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BOILER MAINTENANCE
IMPROVING RELIABILITY AND MANAGEMENT
EXECUTIVE PROFILE
A Q&A WITH ABBS ENRIQUE SANTACANA
MERCURY CONTROL
UNDERSTANDING YOUR OPTIONS
the magazine of power generation
BIOMASS
Co-firing

with
thhe magazine of power generatiion e
1
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YEARS
1304pe_C1 C1 4/4/13 8:59 AM
March 2013 www.power-eng.com
EMISSIONS CONTROL
HYDROPOWER
THE POWER OF REHABILITATION
PRB COAL
CHALLENGES AND SOLUTIONS
Wind Turbine
TECHNOLOGY
CHOICES
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March 2013 www.power-eng.com
EMISSIONS CONTROL
HYDROPOWER
THE POWER OF REHABILITATION
PRB COAL
CHALLENGES AND SOLUTIONS
Wind Turbine
TECHNOLOGY
CHOICES
N
H
A
S
p
e
c
ia
l
A
d
v
e
r
t
is
in
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e
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io
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5
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7
1
1
7
YEARS
A quick start guide to MAXIMIZING our interactive features.
Welcome to the
Digital Edition of
SHARE an article or
page via social media.
Click PAGES to view
thumbnails of each
page and browse
through the entire issue.
Easily browse all BACK ISSUES.
SEARCH for specifc
articles or content.
View the table of CONTENTS and
easily navigate directly to an article.
DOWNLOAD the issue to your desktop.
PRINT any or all pages. SHARE an article via email.
Easily NAVIGATE
through the issue.
Click directly on the page to ZOOM in
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Solvay Chemicals, Inc.
1.800.SOLVAY C (800.765.8292)
www.solvair.us
Copyright 2013, Solvay Chemicals, Inc. All Rights Reserved
On the horizon
The new MATS rule mandates compliance
in two short years!
The Mercury and Air Toxics Standards, or MATS rule, mandates reduction of stack emissions
such as HCl, HF and Hg in coal-fred power plants in just two short years. With compliance
deadlines on the horizon, now is the time to plan a strategy to ensure your power plants
system satisfes the upcoming regulations.
What does this mean to your coal-fred power plant? Bluntly put, it means changing fuels, or
that some air pollution control system must be in place in a very short time to eliminate these
HAPs. It means the need for straightforward information that SOLVAir Solutions can provide
on a systems reduction efectiveness and cost-efectiveness.
When EPA regulations compliance is inescapable, SOLVAir Solutions can help. We have the
expert knowledge of DSI systems and the efective products to help you meet the newest
emissions limitations. Call us today at 800.765.8292 or go to www.solvair.us for more details.
For info. http://powereng.hotims.com RS# 1
1304pe_C2 C2 4/4/13 8:59 AM
www.power-eng.com
1
OPINION
I
ts one of the most legally vulner-
able rules the Environmental Pro-
tection Agency has ever proposed.
The proposed New Source Perfor-
mance Standard, if enacted into law,
would be the frst-ever limit on green-
house gas emissions from U.S. power
plants. The measure would cap CO2
emissions at 1,000 pounds per MWh
for new plants.
If it survives, the measures impact
will reach well beyond new plants and
ripple into the heart of Americas pow-
er sector. Its passage would give the
EPA a green light to pursue CO2 limits
for the nations existing feet of power
plants. By law, the EPA cannot fnalize
CO2 standards for existing plants until
it fnalizes the proposed standard for
new plants. One is inextricably tied to
the other under the Clean Air Act.
The fate of coal-fred generation, the
most important segment of the U.S.
power sector, is at stake.
Ironically, the EPA may be forced to
reduce the rules restrictions on new
plants, if it wants to extend CO2 limits
to the nations feet of existing plants.
The rule, in its current form, would
likely be tossed out by an appeals court
because it fails to provide the fexibil-
ity proffered under the Clean Air Act.
The rule establishes one standard that
can be met by using one type of fuel
natural gas and one type of gener-
ating technology combined cycle. A
coal plant would not be able to meet
the proposed standard without install-
ing a carbon capture and storage (CCS)
system, a risk no utility is willing to
take due to the cost, the liability and
questions about CCS technology.
The Clean Air Act allows the EPA
to set separate standards for each fuel
type coal, oil and natural gas. Whats
more, the law allows a separate stan-
dard based on the best emission reduc-
tion technology for each fuel type.
These allowances are not found in the
GHG rule for new plants. Its also impor-
tant to know the EPA has never set a sin-
gle standard for power plants based on
an emissions limit that can be achieved
by one fuel only and by one technology
with the lowest emissions rate.
The EPAs Mercury and Air Toxics
Standard (MATS) rule was fnalized
and enacted into law last year. Dur-
ing that process, EPA acknowledged it
would be wrong to base standards on
the use of natural gas alone because
those standards would not be techni-
cally or economically achievable for a
coal-fred unit.
The same approach should be used
in setting CO2 limits for new, modi-
fed and existing power plants in the
U.S. A single standard that favors gas
does not promote a competitive free
market and threatens the power sec-
tors ability to establish a diverse, af-
fordable and reliable energy mix.
Setting a single CO2 limit for all
new power plants is like mandating a
single fuel economy standard for all
new cars and trucks. Its irrational and
irresponsible, and it would discourage
investments in more effcient, cleaner-
burning technologies for the nations
abundant supply of coal.
To withstand a legal challenge from
coal-fred power producers, the EPA
should rewrite or re-propose the GHG
rule to accommodate coal and gas, as
it has done in the past. The rule should
include a reasonable standard for coal
plants that can be met without adding
carbon capture equipment, a costly
and problematic technology.
Dominion CEO Tom Farrell put
it like this as he testifed before the
House Energy and Commerce Com-
mittee last year: Standards can be set
to reduce emissions and stimulate the
deployment of advanced generating
technologies without eliminating a
major domestic fuel source.
Rethinking the GHG Rule
BY RUSSELL RAY, MANAGING EDITOR
F
O
L
L
O
W

R
U
S
S
E
L
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O
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p
See Russells video blog at
www.power-eng.com
1304pe_1 1 4/4/13 9:09 AM
Power Engineering is the fagship
media sponsor for
TM
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Power Engineering
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FEATURES
No. 4, April 2013
1
1
7
VOLUME
36 Whats New or Improved
in Mercury Controls?
pp
Learn about a wide range of technologies
yy
used for the capture of mercury.
44 The Path to Greater Effciency
Russell Ray, managing editor of Power Engineering, sat down with ABB North
yy
gg
America CEO Enrique Santacana for a Q&A about the future of power generation
in North America and ABBs efforts to help utilities improve performance.
50 Wastewater Minimization:
The Continuing Story
Contributing Editor Brad Buecker examines the trends in water conservation and recovery.
g y g y
26 Improving Boiler Reliability
Thielsch Engineering identifes the challenges in reducing
a units forced outage rate and examines the value of adopting
a comprehensive approach to boiler management.
40 Reaping the Benefts
of Alliance Contracts
Executives from Westar Energy and Day & Zimmermann NPS discuss
the value of alliance contracts and long-term maintenance agreements
in an interview with Russell Ray, managing editor of Power Engineering.
18
CO-FIRING WITH BIOMASS:
A Look at the Virginia
City Hybrid Energy Center
Power Engineering examines the benefts and
challenges of co-fring with biomass in this profle
on the Virginia City Hybrid Energy Center.
DEPARTMENTS
1 Opinion
4 Industry News
8 Clearing the Air
10 Gas Generation
12 Demand Response
14 View on Renewables
16 Nuclear Reactions
60 Ad Index
1304pe_2 2 4/4/13 9:09 AM
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Hitachi offers the latest evolution in SCR NO

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The TRAC
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and signifcantly enhancing the mercury oxidation capabilities at the same time.
1304pe_3 3 4/4/13 9:09 AM
www.power-eng.com
4
INDUSTRY NEWS
B&W starts second
phase of CCS project
Babcock & Wilcox said that its subsid-
iary, Babcock & Wilcox Power Generation
Group, signed a contract with FutureGen
Industrial Alliance to begin the next
phase of the 167 MW FutureGen 2.0 car-
bon capture and storage project in Mere-
dosia, Ill.
The project is an upgrade to an existing
power plant with B&Ws oxy-combustion
technology to capture more than 90 per-
cent of the carbon dioxide emitted. B&W
PGGs scope of work includes the design
of the oxy-combustion system, air qual-
ity control systems, boiler, steel and other
control systems.
SCE says SONGS
can run at full power
Southern California Edison said Unit
2 at the two-unit, 2,100 MW San Onofre
Nuclear Generating Station near San Di-
ego is ready to run at full power. SCE said
fndings from a recent technical evalua-
tion of the facility helps bolster plans to
begin operating the reactor at 70 percent
power for fve months. The plant has
been offine since January 2012 after pre-
mature tube wear was found in the steam
generating system. There is no word on
when Unit 3 will return to service.
Cape Wind earns fnancing
for offshore wind project
Cape Wind signed a term sheet to en-
gage the Bank of Tokyo-Mitsubishi UFJ
as its Coordinating Lead Arranger of
the commercial bank portion of the to-
tal debt fnancing for the 468 MW Cape
Wind offshore wind farm off the coast of
Massachusetts.
BTMU will supply a signifcant amount
of debt capital to pay for development
and construction costs. Barclays is the
fnancial advisor and will work with the
company to raise the remaining funds.
The project is expected to begin con-
struction by the end of the year.
LADWP takes steps
to end use of coal
generation by 2025
The Los Angeles Department of Wa-
ter & Power (LADWP)s Board of Water
and Power Commissioners approved
an amendment to its contract with the
Intermountain coal-fred power plant
in Utah, switching the power supplied
to southern California utilities to a
smaller, natural gas-fred power plant.
L.A. Mayor Antonio Villaraigosa an-
nounced his intent to end the citys use
of coal-fred power by 2025. LADWP
has also been in negotiations to sell its
share of the Navajo Generating Station
in Arizona to the Salt River Project,
and the company plans to stop using
the generation from that plant by 2015.
NRC denies Calvert
Cliffs nuclear license
Members of the U.S. Nuclear
Regulatory Commission upheld the
licensing boards decision to deny a
construction and operating license for
the proposed 1,500 MW Calvert Cliffs
3 nuclear reactor in Maryland. The
decision is the frst time ever that the
NRC has upheld a license denial for a
commercial nuclear reactor, and only
the second time a commercial nuclear
facility has been denied a license at all.
The denial was based on a fnding
that the nuclear plant would have been
owned entirely by a foreign entity, a
violation of provisions of the Atomic
Energy Act. UniStar Nuclear, which
requested the license, is owned by
France-based EDF. The plant would
have used a European Pressurized
Reactor built by Areva, which is
also mostly owned by the French
government.
Solar & wind projects
approved for public lands
The U.S. Department of the Interiors
Bureau of Land Management approved
two solar and one wind power project to
be built on public lands in two states.
The 750 MW McCoy solar and the 150
MW Desert Harvest solar projects are lo-
cated in California, while the 200 MW
Searchlight Wind Energy Project will be
built in Nevada. Interior has approved 37
renewable energy projects, including 20
solar, eight wind and nine geothermal
plants.
Wisconsin Public
Service to use new kind
of emissions control
Wisconsin Public Service Corp. was
approved to use regenerative activated
coke technology, or ReACT, at the 321
MW Weston 3 boiler in Wisconsin. The
plant will be the frst in the U.S. to use
the system, expected to cost around $275
million.
The technology has been used in Japan
for many years and successfully demon-
strated as part of an Electric Power Re-
search Institute project at Sierra Pacifc
Powers North Valmy Station.
Installation is expected to be complet-
ed in 2017.
Three New England states
team to bring down
renewable energy costs
Connecticut, Vermont and Massachu-
setts offcials are planning joint solicita-
tions for renewable energy to create a
buyers market and drive down costs of
renewable energy, according to a report
from Platts.
Connecticut said it also plans to in-
crease its renewable portfolio standard
and allow large hydroelectric projects to
participate. The report also said Rhode
1304pe_4 4 4/4/13 9:09 AM
Powerplant Engineering
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Please, contact us for our
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1304pe_5 5 4/4/13 9:09 AM
www.power-eng.com
6
INDUSTRY NEWS
will serve as the foundation for all of
the nuclear island structures, includ-
ing the containment vessel and the
shield building. Unit 3 is scheduled to
go online in 2017 and Unit 4 will fol-
low in 2018.
South Carolina Electric & Gas placed
the nuclear island basemat for the V.C.
Summer Unit 2 in South Carolina. The
two 1,117 MW Westinghouse AP1000
reactors are expected to begin opera-
tion in 2017 and 2018.
Siemens opens largest
wind research facilities
Siemens has opened two new research
and development test facilities for wind
turbine technology in Denmark.
A test center in Brande features test
stands for major components of Siemens
wind turbines, including generators,
main bearings and complete nacelles.
The second center, located in Aalborg,
has seven blade test stands capable of
performing full-scale tests of rotor blades,
including a 75-meter blade.
Dynegy buying Ameren
subsidies in Illinois
Dynegy and Ameren signed a defni-
tive agreement in which Dynegys sub-
sidiary, Illinois Power Holdings LLC,
will acquire Amerens subsidiary Ame-
ren Energy Resources and its subsid-
iaries Ameren Energy Generating Co
(Genco), AmerenEnergy Resources Gen-
erating Co. (AERG) and Ameren Energy
Marketing Co. (AEM).
The deal is expected to close in fourth
quarter 2013.
When the transaction is closed,
Dynegy will own 8,000 MW of gener-
ating capacity in Illinois, including the
Duck Creek, Coffeen, E.D. Edwards,
Newton and Joppa power plants.
Prior to closing the deal, Ameren or
a subsidy will purchase three natural
gas-fred power plants from Genco for
a guaranteed minimum price of $133
million.
Darlington nuclear plant
refurbishment approved
The Canadian Nuclear Safety Com-
mission approved plans for Ontario
Power Generation to refurbish and
extend the operating life of the 3,512
MW Darlington nuclear power plant.
The project would include refurbish-
ing all four reactors at the plant, add-
ing 25 to 30 years to their lifespans,
and replacing a number of major com-
ponents while the reactors are offine.
EPA considers revising rule
to regulate GHGs at new
coal-fred power plants
The Obama administration may revise
a rule that would regulate greenhouse
gases (GHGs) from new power plants, ac-
cording to The Washington Post.
The revisions could delay tougher re-
strictions on new power plants and might
allow the EPA to set a separate standard
for coal-fred power plants. The original
rule limited the emissions of GHGs from
new power plants but did not set restric-
tions on existing coal-fred power plants.
Under the current proposed rule, new
plants must emit no more than 1,000
pounds of carbon dioxide per MWh of
electricity produced.
Concrete pours signal start
of construction at Vogtle
Unit 3 and Summer Unit 2
Georgia Power completed the place-
ment of basemat structural concrete for
the nuclear island at its Plant Vogtle Unit
3 expansion site. The placement encom-
passes approximately 7,000 cubic yards
of concrete six feet in thickness, which
Island and New Hampshire may partici-
pate in the second solicitation.
U.S. installs more than
3,300 MW of PV in 2012
Installation of photovoltaics in 2012
increased 76 percent over 2011 numbers
to 3,313 MW, with an estimated market
value of $11.5 billion, according to GRTM
Research in partnership with the Solar
Energy Industries Association.
Cumulative PV capacity operating at
the end of 2012 was 7,221 MW.
The U.S. accounted for 11 percent of all
global PV installations in 2012.
The report predicts the U.S. PV market
will grow 30 percent in 2013 with 4.3 GW
of new PV added during 2013 across all
market segments.
California led the U.S. in 2011 with
1,033 PV installations. Arizona was sec-
ond with 710, followed by New Jersey
with 415, Nevada with 198 installations
and North Carolina with 132 to round
out the top fve.
NuHub, Holtec team in
second round of bids for
SMR funding
NuHub is partnering with Holtec In-
ternational to develop small modular
reactors (SMR) using funding from the
U.S. Department of Energy. DOE recently
made up to $226 million available to sup-
port the development of SMRs.
Holtec has already designed an indig-
enously developed SMR, the 160 MW
SMR-160, and NuHub will help support
the companys application to the DOE.
Babcock & Wilcox won the frst round
of SMR funding.
1304pe_6 6 4/4/13 9:09 AM
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8
CLEARING THE AIR
20 tpy and PSD permitting is required for
both PM
10
and PM
2.5
. For my construc-
tion permit application, I run a screening
model for just the new auxiliary boiler.
The screening model results in a 24-hour
average concentration of 1 microgram
per cubic meter (g/m
3
) for both PM
10

and PM
2.5
. The PM
10
modeling is com-
plete since the results are below both the
SIL and SMC. But since there is no lon-
ger a SIL or SMC for PM
2.5
, I now have to
run a refned model and include not only
the two pulverized coal boilers, cooling
tower, emergency fre pump, plant haul
roads, coal handling and coal storage
piles at my plant but also all emission
sources at neighboring facilities within
at least 50 km from my plant (in most
states). This is considerably more effort,
cost and time. Additionally, without an
SMC, I now have to procure and operate
an ambient air monitor to conduct one
year of preconstruction monitoring data
unless I can convince the state agency to
let me use data from one of the monitors
that they operate. (Some states do not
allow their monitors to be used for this
purpose). My application now involves
a major demonstration and a severe
schedule impact for a trivial ambient air
impact.
Adding to the confusion, some states
have incorporated EPAs SILs and SMC
by reference; others have explicitly listed
them in the state regulations. The result is
a state-by-state determination of whether
or not this ruling has immediate impact
or must wait until state implementation
plans are modifed.
Once again, uncertainty, confusion,
and a lack of common sense remain the
rule in air permitting.
T
hings change fast in air disper-
sion modeling. Immediate ef-
fects occur from tightened stan-
dards, shorter averaging times and new
pollutants. One consistency, however,
has been that EPA has allowed small im-
pacts to occur without requiring a full
dispersion model. Until now.
The foundation of the Clean Air Act
is the designation of the National Am-
bient Air Quality Standards (NAAQS)
and the classifcation of each county in
the U.S. as having acceptable air qual-
ity (attainment) or bad air quality (non-
attainment). The criteria pollutants for
which air quality is commonly mod-
eled are nitrogen dioxides (NO
2
), sulfur
dioxides (SO
2
), carbon monoxide (CO),
particulate matter less than 10 microns
in diameter (PM
10
) and, most recently,
particulate matter less than 2.5 microns
in diameter (PM
2.5
).
A dispersion model is initially run just
for a projects new or modifed emission
sources for comparison to the model-
ing signifcant impact levels (SILs) and
signifcant monitoring concentrations
(SMCs). The SILs and SMCs are screen-
ing tools the EPA uses to determine
whether a new source may be exempted
from certain New Source Review require-
ments. The SIL is a de minimis thresh-
old used to determine whether a source
may cause or contribute to a violation of
prevention of signifcant deterioration
(PSD) increment or the NAAQS, in other
words, a signifcant deterioration of air
quality. The SMC is an increase in ambi-
ent concentrations of pollution, below
which EPA exempts a source from the
PSD program requirement to gather and
submit one-year pre-application ambient
monitoring data.
EPA had proceeded with this screening
methodology since the earliest days of
NAAQS compliance. Then the Court of
Appeals for the District of Columbia re-
jected EPAs rules governing the SIL and
SMC for new sources of PM
2.5
(Sierra Club
v. EPA, issued January 22, 2013). In oth-
er words, there are no SILs or SMCs for
PM
2.5
and all PSD projects must conduct
a refned modeling analysis in addition
to providing one year of pre-construction
monitoring (or use a representative exist-
ing monitor).
PM
2.5
is distinct from the other pol-
lutants, which have had NAAQS for de-
cades; PM
2.5
was added in 1997. However,
only the PM
2.5
SILs are found in the CFR;
the other SILs are not, nor are they found
in any other regulation. The authority
for the NO
2
, SO
2
, CO and PM
10
SILs is
merely written guidance and memos
from EPA. And yet, its the codifed PM
2.5

SIL that was revoked by the court. (The
SMCs are found in the Code of Federal
Regulations at 40 CFR 52.21(i )(5)(i).)
The SILs and SMCs streamline the per-
mitting process, allowing focus on bigger
projects with non-trivial impacts. If the
screening model results for a pollutant/
averaging period combination are below
the signifcance levels, no further model-
ing is required for that combination.
Heres an example to show how the
SILs and SMCs work. The SIL and SMC
for 24-hour average PM
10
are 5 g/m
3

and 10 g/m
3
, respectively. My coal-fred
power plant has two pulverized-coal
boilers, a cooling tower and an emergen-
cy fre pump. I want to construct an aux-
iliary boiler. For the sake of this example,
lets assume the particulate emissions are
PM
2.5
: Goodbye
Insignifcance
BY ROBYNN ANDRACSEK, P.E., BURNS & MCDONNELL AND CONTRIBUTING EDITOR
1304pe_8 8 4/4/13 9:10 AM
1304pe_9 9 4/4/13 9:10 AM
www.power-eng.com
10
GAS GENERATION
are developing two major coal gasifca-
tion projects with very high capture rates.
Linde is a technology supplier to these
projects and a strong partner. It is our
view that focusing on natural gas plants
for CCS also makes good sense. The tech-
nology is ready and we believe there are
opportunities to develop these plants
today. While it is true that widespread
deployment of CCS has faltered in recent
years because of the lack of strong policies
to reduce emissions, Summit has been
pursuing a carbon capture strategy that
couples the emerging market for cleaner
electricity with the strong demand for
CO2 in the oil industry for enhanced oil
recovery (EOR) activities.
The utilization of CO2 for EOR as it is
being injected underground for perma-
nent storage generates additional reve-
nues to help pay the costs of CO2 capture.
The smaller scale of natural gas based
projects, from both a capacity and a capi-
tal cost standpoint, and their ability to de-
ploy in different regions than coal plants,
are some of the reasons behind Summits
move into this area. An ability to offer a
new clean product to electricity purchas-
ers and to participate in additional mar-
kets, beyond power, are other factors that
make this technology platform appeal-
ing. The long-term strategic advantage is
also signifcant. The environmental and
energy security benefts these projects
will bring are compelling. They will
produce a superior electricity product
(ultra low-carbon and fully baseload)
and a superior oil product (domesti-
cally produced from existing wells).
Summit Carbon Capture has a strategy
to develop these projects today.
There are many attractive technologies
that fail to break into the marketplace due
to an inability to compete economically.
T
hose in the power industry are
keenly aware that we are in a
period of profound transition.
The most signifcant driver of change has
been the surge of new natural gas sup-
plies entering the domestic marketplace.
What was once considered a diminish-
ing fuel has now become the reference
against which all electricity projects must
compete. Power from natural gas com-
bined cycle plants is effcient, clean, low
cost and results in half the carbon dioxide
(CO2) of a like-sized coal plant. These
characteristics have rearranged the dis-
patch order in many electricity markets.
Many believe this leads to an outcome
that is simple and irrefutable natural
gas power plants are poised to become
the dominant resource in our electricity
system for decades.
But how will todays conditions af-
fect our long term energy mix? There are
many things we cant predict. Gas prices
(and production costs) could begin to
rise as domestic demand and exports
increase, along with stricter environmen-
tal regulation gas production methods.
Further advances in technology should
continue to reduce the costs of alternative
power sources. Finally, environmen-
tal regulations will play a large role in
shaping our energy mix in other ways,
most signifcantly through require-
ments to lower CO2 emissions, which
appear inevitable.
Our company, Summit Power Group,
recently announced it has teamed up
with the international technology and
engineering frm The Linde Group in a
non-exclusive initiative to develop com-
mercial scale natural gas combined cycle
power plants that capture up to 90 per-
cent of their CO2. Summit is no stranger
to carbon capture and storage (CCS). We
Based on the market conditions described
above, namely low cost gas supplies driv-
ing down electricity prices and emissions
(as gas increasingly offsets coal), how will
natural gas facilities with CO2 capture be
competitive? Naturally, these plants are
more expensive than an equivalent plant
without capture. The revenues from sell-
ing CO2 to the oil felds will help make
up for a large part of this difference. Even
so, a modest premium on the power price
(or some other revenue stream) will gen-
erally be required. In contrast to most
new gas plants that are fexible in their
dispatch, these carbon capture facilities
will need to operate primarily in basel-
oad in order to perform most effciently
with carbon capture equipment. But just
as the intermittencies of renewable ener-
gy have been accommodated in the mar-
ketplace, there will likewise be a place for
these plants as baseload needs of utilities
grow, including through retirements of
other baseload plants.
Like renewable energy sources that
have thrived despite the lack of overarch-
ing policies rewarding CO2 reductions,
natural gas plants with CO2 capture can
gain a foothold in todays energy markets
with creative development concepts and
some helpful nudges from policy makers
and regulators. Companies that are suc-
cessful in this environment will be well
positioned for even greater success as
CO2 regulations are enacted. Our coun-
trys increased reliance on natural gas has
begun to lower CO2 emissions after years
of stubborn growth. Carbon capture can
ensure that abundant supplies of natural
gas beneft our country for decades. With
carbon capture, natural gas like coal
with carbon capture can be a low-car-
bon energy source for the future and not
just a bridge to get us there.
The Dash for Gas
BY SASHA MACKLER, VICE PRESIDENT OF SUMMIT CARBON CAPTURE, SUMMIT POWER GROUP LLC
1304pe_10 10 4/4/13 9:10 AM
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12
DEMAND RESPONSE
end-to-end integration, installation,
and DR program design. Success-
fully spanning this breadth requires
a detailed understanding of the end-
to-end DR architecture, including
back-offce systems, the smart grid
platform and network, smart me-
ters, and customer HAN endpoints.
A customer engagement platform
designed to keep participation high,
especially in price response pro-
grams. This platform must support
any endpoint, any meter type, and
any customer type.
Support for end-to-end SLAs and
performance guarantees. Utilities
may fnd it diffcult to negotiate
SLAs for every component in the DR
solution, and still may not end up
with the performance they need.
Choice within an integrated solu-
tion. The utility must be free to
choose among a selection of sup-
ported meters, customer endpoints,
back-end software including inter-
nally developed systems, and other
components of the DR solution.
Experience, with a proven track re-
cord of successful smart grid-based
DR implementations.
Smart grid-based DR is available today
and is already helping numerous utili-
ties expand their load control programs,
implement new pricing programs and
advanced load shedding strategies, and
achieve other benefts for themselves
and their customers. As evidenced by the
all-time high customer satisfaction for
OG&E, by re-thinking existing processes
and vendor relationships, utilities can
leverage smart grid technologies to gain
new benefts.
T
he smart grid enables a new
multi-vendor approach to de-
mand response (DR) that gives
utilities and their customers greater
choice and delivers up to 40 percent
more benefts than traditional DR of-
ferings. For example, Oklahoma Gas &
Electrics SmartHours DR initiative saved
an average of $191 for each of its 44,000
participants and enabled more than 67
MW of potential system peak load capac-
ity through 2012.
Historically, utilities have implement-
ed single-vendor, one-way communi-
cation DR solutions, giving operators
no visibility into participation patterns
and making event prediction diffcult.
Nor could operators tell if a load con-
trol switch is working, leading to lower-
than-expected load shedding and un-
necessary truck rolls.
In contrast, a smart grid network pro-
vides highly reliable and secure two-
way communications, eliminating the
need for separate DR communications
infrastructure. This gives utilities a cost-
effective way to expand load control
programs to all customers with no im-
pact on regulatory approvals for existing
initiatives. More importantly, two-way
communications enables an entirely
new paradigm for DR.
Two-way communications opens
new avenues for engaging customers,
including via mobile phone and the
web. For example, OG&Es SmartHours
DR program can log into personalized
web sites providing real-time energy
usage and billing information.
Two-way communications also en-
ables new pricing programs and rate
plans, as well as new options within a
load control program that include the
option for customers to participate in a
load-control event simply by pressing a
button on their thermostat. In addition,
operators get granular feedback for each
load control event, simplifying load re-
duction verifcation and future load shed
predictions. Operators also gain visibility
into device operation and health, simpli-
fying maintenance, increasing reliability,
and reducing costs.
A standards-based smart grid grants
utilities freedom of choice, freeing them
to mix and match load control devices,
software, and other components from
multiple vendors. Operators can choose
best-of-breed thermostats, load control
switches, EV chargers and other devices
and can easily swap them out as needs
change.
PICK THE RIGHT PARTNER
Reaping the full benefts of smart-
grid based DR requires re-thinking
existing processes and a different ap-
proach to sourcing and vendor relation-
ships. A key challenge is ensuring all
smart grid and DR components work
together, end to end.
Depending on system integration
requirements, utilities may need to
add staff or consultants for testing and
validation and to tie into existing DR
management systems and back-offce
software. Standards-based solutions
simplify the integration process and re-
duce potential problems.
However, utilities can minimize inte-
gration issues and maximize their return
on investment by selecting one vendor to
be responsible for their DR solution.
When selecting a smart grid DR ven-
dor, look for:
The ability to take responsibility for
Demand Response in a Smart Grid World
New Approaches,
New Benefts
BY MATT SMITH, HEAD OF DEMAND SIDE MANAGEMENT, SILVER SPRING NETWORKS
1304pe_12 12 4/4/13 9:10 AM
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14
VIEW ON RENEWABLES
lithium extraction techniques to trans-
form mined materials into saleable
products cost-effectively.
The best way of increasing the value
of brines is by improving the effciency
and reducing the cost of power
generation technologies. The DOEs
Pacifc Northwest National Laboratory
is in the process of developing
microporous metal-organic solids
as the primary heat carrier and heat
transfer medium that could increase
power generation at binary plants by
15 percent.
Finally, by using water produced
in oil and gas and mining processes,
geothermal developers can leverage
existing infrastructure and greatly
reduce the cost of development,
conversely increasing the value of the
fuid stream. ElectraTherm, another
industry partner, is demonstrating
this waste heat-to-power technology
at Florida Canyon Mine in Imlay,
Nev. by using existing groundwork
for a fraction of the cost of new
development. This project developed
an optimized solution for power
generation using co-produced
geothermal fuids that will produce a
constant 75kW of electricity.
While DOEs efforts to improve
access to subsurface resources in
a competitive manner will yield
signifcant results, U.S. industry can
spur even more dramatic growth by
increasing the value of geothermal
fuids. With a greater rate of return,
these near-term technologies can
deliver early successes that will reduce
geothermal development costs in the
long-term.
I
nvestments by the U.S. Depart-
ment of Energy (DOE) are help-
ing to produce geothermal power
at increasingly lower temperatures.
While traditional geothermal energy
relies on geologically rare hot spots in
the subsurface, new technologies are
making inroads with economics that
could bring valuable returns on geo-
thermal investment in the near-term.
Geothermal resources are reservoirs
of hot fuid (brine) that exist below the
Earths surface. Wells can be drilled
into these underground reservoirs
to tap steam and very hot brine that
can then be brought to the surface to
generate electricity. In the U.S., most
conventional geothermal reservoirs
are located in the western states, which
enjoy a predominance of geological
anomalies that allow for relatively
shallow and hot geothermal reservoirs
to be accessed economically, creating
electricity via turbine-generators (TG).
Traditionally, these hot zones have
been the main focus of geothermal
development, as these resources can be
directly used in a TG set via dry-steam
or fash-steam technologies.
The development of binary tech-
nology, however, has allowed for an
expansion of the temperature range
of resources capable of producing elec-
tricity. In these systems, low to mod-
erately heated geothermal fuid (be-
low 300F) and a secondary (hence,
binary) fuid, with a lower boiling
point than water, pass through a heat
exchanger, where the heat causes the
secondary fuid to fash to vapor, driv-
ing the TG.
The DOEs Geothermal Technologies
Offce (GTO) develops and deploys a
portfolio of innovative technologies
for domestic power generation. Within
this offce is the low temperature and
co-produced resources subprogram
that conducts research and demon-
stration projects in partnership with
industry that will lead to advanced
geothermal energy use and electric-
ity production from these lower tem-
perature fuids. But, to truly capitalize
on lower temperature resources, the
value of produced fuid must be in-
creased.
There are a number of ways to
improve the value of geothermal
fuid. One is through cascaded
technologies, in which the geothermal
fuid cascades from the highest
available temperature for creating
electricity down through direct use
applications that require successively
less heat, including spas, industrial
processes and snow melting each
with distinct temperature ranges.
The GTO is helping to develop this
process through a number of projects,
including one in partnership with the
Surprise Valley Electrifcation Corp
(SVEC). The SVEC project will produce
over 3 MW of power from geothermal
fuid which will then be used for
aquaculture and irrigation purposes.
Another improvement is the har-
vesting of valuable materials from geo-
thermal fuid. In addition to using the
heat to create power, another project
partner, Simbol Materials, is develop-
ing techniques to proftably extract
strategic minerals from brines via new
geothermal mining technologies.
The project is validating improved
New Ways to Produce
Geothermal Power at
Lower Temperatures
BY TIM REINHARDT, PHYSICAL SCIENTIST, DOES GEOTHERMAL TECHNOLOGIES OFFICE
1304pe_14 14 4/4/13 9:10 AM
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16
NUCLEAR REACTIONS
two key projects:
The Henry Hub natural gas spot
price, which averaged $2.75 per mil-
lion British thermal units (MMBtu)
in 2012, will average $3.53 per
MMBtu in 2013 and $3.84 per
MMBtu in 2014.
Looking farther out to 2040, the
EIA projects natural gas prices to in-
crease 3.5% and electricity prices to
rise 2.0% by 2040.
Although the EIA predicts only slight
increases in gas prices, there are a num-
ber of possible scenarios where gas prices
increase more sharply. Power industry
leaders know the volatile history of natu-
ral gas prices and the impact of disruptive
forces on that market. Coal plants and
some nuclear power plants are retiring
more quickly than expected and as gas
is burned increasingly for baseload gen-
eration, it will put additional pressure on
demand for gas. Gas turbine combine
cycle (GTCC) plants are very sensitive to
gas price spikes because they require a
continual fow of fuel. If nuclear power
becomes less of a player in generating
baseload, that could also put pressure on
natural gas prices, as would increased reg-
ulation of fracking for shale natural gas.
Although shale natural gas initially ap-
pears to be the death of nuclear power,
these two resources actually beneft one
another. Nuclears continued baseload
presence can help moderate price fuc-
tuations (and demand shocks) while the
market fnds a sweet spot for natural gas
prices that makes development worth-
while but not prohibitive. As natural gas
prices edge up a bit, they elevate electric-
ity prices to a point that keeps nuclear
power viable.
N
atural gas and nuclear power
have stayed in the headlines
as they appear poised for as-
cendance or peril, with their destinies
intertwined. They were both in the news
when President Obama announced his
nominees for Secretary of Energy and
head of the EPA. Nuclear power and nat-
ural gas were also hot topics at this years
IHS CERAWeek conference in Houston.
Together, natural gas and nuclear power
may keep electricity prices low, the grid
stable and carbon emissions greatly re-
duced in the United States.
Nominees Ernest Moniz to run the
DOE and Gina McCarthy as head of the
EPA were seen as signs that the President
plans to make real progress on climate
change as both individuals are expe-
rienced Washington, DC insiders who
know how to get things done. Moniz was
a member of the Blue Ribbon Commis-
sion on Americas Nuclear Future and
supports the roles of both nuclear power
and natural gas in reducing carbon emis-
sions. McCarthy is experienced in clean
air regulation and is known as data driv-
en and fact-based in her approach.
At the CERAWeek conference, Micro-
soft Corp co-founder and Chairman
Bill Gates touted the benefts of nuclear
power and called for more investment in
nuclear energy research. Gates stated that
nuclear power provides reliable, baseload,
low-carbon energy, while renewables are
intermittent, subsidized, and their appli-
cation is signifcantly limited by current
storage capabilities. Gates also discussed
the possibilities of improved nuclear
power reactor designs with greater inher-
ent safety features, which he said are cur-
rently under development in China.
Natural gas was also a hit at CERAWeek,
and likely the most popular topic. Given
the extent of our shale reserves and pipe-
line infrastructure, the United States
appears best positioned to supply the
growing Asian demand for natural gas.
Potential investors in more export termi-
nals and facilities to liquefy natural gas in
order to ship it overseas are waiting to see
if the Obama administration agrees to ex-
port the fuel to various countries that do
not have free-trade agreements with the
United States. The DOE is responsible for
making determinations regarding lique-
fed natural gas (LNG) export permits.
Of course, there are foes and proponents
of exporting LNG from the U.S. Those
against increasing LNG exports on com-
mercial grounds fear higher natural gas
prices.
There is evidence to suggest that natu-
ral gas prices have bottomed out and
are likely to rise over the next few years,
but probably not by much. Supply and
demand of course are the major factors
determining natural gas prices, but there
are a multitude of contributors infuenc-
ing supply and demand. Demand is af-
fected by region of the country, time of
year, weather patterns and strength of the
economy. Supply is impacted by pipeline
development, the number of rigs com-
panies decide to deploy at any point in
time, the amount of storage and the level
of LNG exports and imports, to name a
few. Other price impacts include the price
of oil, expectations regarding the extent
of accessible (mostly shale) natural gas re-
serves and how fast you think natural gas
wells decline in production year over year
(30-40 percent).
So, taking these variables and others
into account the U.S. Energy Informa-
tion Administration (EIA) has made
Natural Gas and Nuclear
Power Double Play
BY MARY JO ROGERS, PH.D., AUTHOR OF NUCLEAR ENERGY LEADERSHIP: LESSONS LEARNED FROM U.S. OPERATORS.
1304pe_16 16 4/4/13 9:10 AM
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18
a co-fred power plant located in Wise
County, Va. that can burn both coal and
biomass.
In the case of Virginia City, we were
taking advantage of available fuels in
the area, plus we had renewable in
mind right from the beginning, Do-
minions Director of Generation Proj-
ects Mark Mitchell said.
relying too heavily on one type of fuel
throughout a companys feet.
The idea of fuel diversity, however,
does not need to be something applied
through an entire feet of facilities. The
same idea can be applied to burn a mix-
ture of fuels in one power facility, which
was Dominions idea when it designed
the Virginia City Hybrid Energy Center,
CO-FIRING WITH BIOMAS
A
s power companies look
to deal with stronger
federal regulations and
a focus on renewable en-
ergy, many talk about
maintaining fuel diversity using a va-
riety of generation methods to not only
meet overall emissions requirements, but
also stabilize prices for customers by not
The Virginia City Hybrid Energy Center is
capable of burning up to 20 percent biomass
in its fuel load. Photo courtesy of Dominion
and Clisso Photography.
a co fred power plant located in Wise relying too heavily on one type of fuel s power companies look
A Look at the Virg
Hybrid Energ
BY JUSTIN MARTINO, ASSOCIATE EDITOR
1304pe_18 18 4/4/13 9:10 AM
www.power-eng.com
19
CONTINUED ON PAGE 22
Using a variety of fuels in one plant
The 600 MW Virginia City Hybrid
Energy Center, which cost just less than
$1.8 billion, is capable of burning up to
20 percent of biomass in its boilers along
with coal. In addition, Mitchell said the
plant is capable of burning types of coal
that are common in the area.
What you have going on in Virginia
SS:
The Virginia City facility uses two Foster
Wheeler circulating fuidized bed boilers to
burn local coal, coal waste and wood for
power. Photo courtesy of Dominion.
City is essentially your own localized fuel
diversity through the capability to use va-
roius types of coal in the region as well as
biomass, Mitchell said. Some of those
coals, other plants probably cant use.
For instance, we utilize a large amout of
waste coal, which cannot be used by typi-
cal power plants. Its a small fuel diversity
plant in itself, and I think that will help
stabilize the pricing to some extent.
Burning biomass was considered a key
part of the plants design from the begin-
ning. The plant is designed to burn up
to 20 percent biomass in its system, al-
though the exact amount of biomass that
is burned will depend on economic con-
siderations, Mitchell said.
Like many biomass facilities that burn
wood, the Virginia City facility uses
wood that cant be used by many other
commercial operations. Danny Woods,
plant operator of the Virginia City Hy-
brid Energy Center, said the majority of
the biomass being burned by the plant is
comprised of wood chips. Many biomass
facilities use waste wood, often sticks and
small branches from treetops.
Using a variety of fuels in one plant City is essentially your ownlocalizedfuel
ginia City
gy Center
1304pe_19 19 4/4/13 9:10 AM
www.power-eng.com
20
When We Energies made a commitment to build a $250
million biomass facility, the companys commitment to eff-
ciency didnt stop at just building a power facility that utilizes
renewable resources.
Before the company began planning its new biomass facility at
the Domtar Corporations paper mill in Rothschild, Wis., We Ener-
gies started by looking for partners for the
project with the goal of creating a model of
the effectiveness of energy recycling.
We made a commitment that we were
going to propose a project like this in this
state, and so we went through a request
for proposal process sort of a screening
process with literally every paper mill in this state, We Energies
Asset Manager Terry Carroll said. We went to the Wisconsin Pa-
per Council to see who in their membership might be interested in
working with We Energies on the development of a plant like this.
The result of the partnership between Domtar and We Energies
is a 50 MW biomass-fred cogeneration plant that not only pro-
vides power for We Energies customers, but provides all the steam
for the processes at Domtars paper mill.
Carroll said the project fts a variety of needs for both compa-
nies. We Energies is able to use the project to ft into its production
requirements for Wisconsins renewable portfolio standard law,
which requires the company to procure about 8.2 percent of its
retail sales as renewable energies by the year 2015. Domtar is able
to shut down its existing boilers and allows them to eliminate the
companys dependence on natural gas.
The facility will use a circulating fuidized bed boiler fred by
waste wood left from existing forestry operations, mostly coming
from the treetops of trees already being harvested by saw mills
and paper mills.
There is more than enough fuel, Carroll said, adding that We
Energies conducted multiple wood availability studies over the past
several years. In fact, theres a surplus of this type of material.
Were not going to be cutting new trees down.
The facility, which is being built under a contract with The Boldt
Company, is about 80 percent complete, according to Myron
Wagner, project manager for The Boldt Company. We Energies
contracted with Metso Power for the boiler, and the steam turbine
generator is from General Electric. The distribution control system
for the facility is from Emerson, and the company also installed a
natural-gas fred boiler from Cleaver Brooks to use as a backup
when the main boiler is shut down for maintenance.
Poyry is serving as the engineering contractor for the plant,
which will be owned by We Energies and operated by Domtar un-
der an operating contract.
Wagner said the main difference in the plant as opposed to a
typical coal-fred plant is in how the fuel is delivered to the bed of
the boiler and what substance is used in the bed of the boiler. The
Rothschild project uses sand in its bed, as opposed to many other
boilers that use limestome for sulfur capture.
We dont have sulfur to capture because wood is very, very low
in sulfur, Carroll said.
By allowing Domtar to shut down its current boilers, the project
will actually lower the emissions produced from the paper mill.
Because Domtar is shutting down their old boilers, this project
actually reduces air emissions in the area by 30 percent, Carroll
said. So even though were building a larger facility than was here
before, its a net reduction in overall emissions for the plant.
While We Energies also has several wind projects in the area,
Carroll said the biomass facility will have a capacity factor advan-
tage over a wind or solar project. The Rothschild facility will use
about 500,000 tons of biomass a year for the fuel supply and
could produce around 400,000 MWh annually, depending on
dispatch requests from the Midwest Independent Transmission
System Operator market. That equals the production of one of the
companys 162 MW wind power projects.
The advantage of a biomass plant over wind is this project is
dispatchable, whereas with wind and solar you sort of take it as its
made, Carroll said. Theres really no control over when the wind
blows or when the sun shines, but there is control over the amount
of energy that is generated from a steam turbine generator.
The facility also serves as a frst of a kind model for We Ener-
gies when developing a project by working so closely with a part-
ner to maximize effciency, Carroll said. The two companies are
partners not only in the plant, but also in procuring wood. Domtar
also treats the wastewater from the plant at its facilities.
We have an excellent relationship with Domtar, both as a cus-
tomer because theyre buying steam from the plant, and as an
operating entity and as the host of the facility, Carroll said. There
are a lot of dimensions to this relationship. Theyre just an excellent
partner weve been very pleased to work with.
Domtar Project Touts the Benefts of Biomass
BY JUSTIN MARTINO, ASSOCIATE EDITOR
We Energys biomass facility at
the Domtar Corporation paper
mill in Wisconsin will provide
50 MW of power as well as
produce all the steam needed
for the mill. Photo courtesy of
The Boldt Company.
1304pe_20 20 4/4/13 9:10 AM
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CONTINUED FROM PAGE 19
Although the plant was designed to burn biomass, a late
addition to its air permit makes burning biomass a require-
ment. The facility must burn 5 percent biomass at the end of
three years of operation, with that number eventually going
up to 10 percent if burning wood is economically feasible.
Mitchell said he presumes the air board had an interest in
the plant using biomass and is encouraging the company to
continue on that path by putting the requirement into its air
permit, but the company expects to have no issue meeting
those standards.
Thats really no concern of ours, he said. We plan on
using all the wood we can get.
Designing a plant to burn multiple fuels
The key to Virginia City Hybrid Energy Centers ability to
burn multiple types of fuel is its technology. The plant uses a
circulating fuidized bed boiler, a style of boiler that is multi-
ple decades old but is capable of burning many types of fuel,
making it ideal for burning biomass.
The reason a circulating fuidized bed boiler is well suited
for this application is you can burn just about anything in
them, said Myron Wagner, project manager for The Boldt
Company.
The Boldt Company is currently constructing a biomass
facility in Wisconsin that uses wood as its main source of fuel
(see sidebar), although Wagner added the boilers can also be
used to burn anything from coke fuel to tires.
The Virginia City Hybrid Energy Facility uses circulating
fuidized bed boilers to fre a single steam turbine. Foster
Wheeler produced the two boilers, and Mitchell said one rea-
son that company was chosen was because of its experience
with fring biomass in its boilers.
Although the circulating fuidized bed burners have been
in use for a while, Woods said the boilers have not tradition-
ally been used in plants with the output of the Virginia City
facility.
I believe this technology was being built in the late 70s,
but it has never been built to this magnitude, he said. Just
recently theyve been building them this size with this type
of output. There are not too many units this size in the Unit-
ed States.
The steam produced by the boilers power a single 690 MW
Toshiba steam turbine, and the air-cooled condenser, which
is one of the largest in the nation, was provided by SPX Cool-
ing Technologies. Emerson Process Management supplied
the distributed control system for the facility.
The bed of the boiler is made of ash from the combustion
of the fuel and injected with limestone, which helps capture
some emissions from the fring process. In addition, the
plant uses a dry scrubber, baghouse particulate flter, selec-
tive non-catalytic reduction system and an activated carbon
ejection system to minimize mercury emissions.
1304pe_22 22 4/4/13 9:10 AM
www.power-eng.com
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Virginia City is a new, modern plant, Mitchell said. It
has all the latest environmental controls to minimize emis-
sions.
Working through challenges in the process
The Shaw Group, now part of Chicago Bridge and Iron Co.,
was awarded an engineering, procurement and construction
contract for the facility in 2007 and announced in July 2012
that it had achieved substantial completion of the project,
which began burning coal commercially on July 11, 2012.
Dominions plan was to have the plant operating commer-
cially before beginning co-fring biomass, however, and the
process of bringing the co-fring online is still in progress.
Woods said the plant began the commissioning process
for biomass last October, and the process has been slower
than normal as the company works to minimize the risk of
commissioning while meeting the plants commitments on
a daily basis.
He added the process has picked up speed this year, and he
expects the commissioning to be fnalized by the summer.
Were still working through mechanically and electrically
proving out the system and tuning the system as we go, he
said.
So far, the facility has burned about 5,000 total tons of
biomass. Working at its top rating of burning 20 percent bio-
mass, it would burn about 4,000 tons a day, depending on
biomass quality, Woods said. Meeting the air permit require-
ments would require substantially less than that, however.
Woods said that within three years, the facility would burn
about 700 to 800 tons of biomass a day in order to meet the
air permit requirements, although that amount is just a mini-
mum.
If the economics prove to be benefcial to our ratepayers,
and were able to get the supplies of the material, I can see us
burning more than that, he said.
Woods said the plant is working through several issues
with co-fring biomass, with one major issue being control-
ling the fuel fow to maintain the steam fow.
Although the coal supply used by the boilers varies in heat
content, Woods said the facility uses a btu compensator that
will change the fuel fow to maintain a certain steam fow de-
pending on the heat being produced by the boiler. Co-fring,
however, can create problems in maintaining that steam fow
because the biomass has a different, but also varying, heat
input.
With both of those things varying, its very tough to
control and have a consistent output from the unit, Woods
said. Weve got some ideas about keeping the fow of bio-
mass consistent and then varying the coal to keep the steam
fow or the output of the unit the same, but thats going to be
something were going to have to deal with.
Another issue Woods said the plant is dealing with is
1304pe_23 23 4/4/13 9:10 AM
www.power-eng.com
24
Despite the small challenges during
the commissioning process, Woods said
the system has been very reliable and
Mitchell said the facility is going through
a normal startup process.
The benefts of co-fring
The Virginia City Hybrid Energy
spontaneous combustion, which is not
an issue with the type of coal used by the
facility but is a potential problem with
the biomass fuel. In addition, the plant
has been working through various equip-
ment issues that Woods said would be ex-
pected through commissioning.
Those issues include undersized mo-
tors on various pieces of equipment that
conveys the wood as well as having plug-
ging issues in the chutes if the biomass
material is very wet and very fne.
A lot of it has surrounded the material
itself, Woods said. That has caused the
majority of our issues.
To help work out the problem, Do-
minion has turned to its own internal
expertise by bringing in experts from its
Pittsylvania Power station, an 83 MW
biomass facility located in Hurt, Va. The
Pittsylvania station is one of the larg-
est biomass power stations in the east-
ern U.S. In addition, Woods said Foster
Wheeler has employees on site helping
with the co-fring process.
Although the Virginia City facility is currently operating
commercially fring coal, Dominion expects the facility to be
fring at least fve percent biomass within three years. Photo
courtesy of Dominion.
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25
Not necessarily for the EPA regulations;
its an overall combination of regulations,
economics and just our renewable goals.
Each plant is a case-by-case basis based
on regulations and economics.
With increased scrutiny on coal plants,
biomass may become more important as
a source of fuel. Companies will be able
to utilize what is classifed as waste wood,
Center benefts from co-fring in multiple
ways, Woods and Mitchell said. One of
those benefts is the reduced emissions
being produced from the Virginia City
facility because of biomasss lower sulfur
content.
The plant also helps reduce costs to
the customers by allowing the company
to use up to 20 percent biomass at the
facility and choose to use whichever fuel
is most economical at any given time,
Woods said.
The facility also helps Dominion by
helping expand its renewable energy pro-
duction portfolio, both nationally and in
Virginia. Mitchell said Virginia has a goal
of using 15 percent renewable energy by
the year 2025.
We do see biomass as being an eco-
nomic fuel that the market will develop
in the area, which will help the dispatch
rate with the plant, Mitchell said. It also
generates renewable credits that can be
sold, so theres a bit of a plus there.
The biomass aspect of the plant may
have also helped in permitting the con-
struction of a facility that fres coal at a
time where many coal-fred plants are
having diffculties receiving permits and
community support.
Permitting any large facility these
days has its challenges, Mitchell said.
A coal plant in particular has numerous
challenges, but overall the community
was very supportive, and I do think the
renewable part of the plant was a help.
Benefts also extend to the overall
maintenance and wear and tear on the
facility.
From a technical standpoint, you
have a lot less ash being produced by bio-
mass, Woods said. Its a lot less loading
on our ash system, and its a lot less wear,
so thats good all the way around for us.
The future of co-fring
Mitchell said the company has no cur-
rent plans for another co-fring facility,
but that it is converting three coal-fred
plants into biomass plants.
We are looking at swapping some of
our existing coal feet to biomass, he said.
material that might otherwise be left on
the ground in the forest or put in landflls
and turn that wood into a renewable en-
ergy source.
With coals price stability and abun-
dance in the U.S., it is possible more com-
panies will look to get the best from both
fossil fuels and renewable by using both
at the same time.
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1304pe_25 25 4/4/13 9:10 AM
www.power-eng.com
26
About the Authors:
Pamela Smoske is Executive Director of
Development and Operations, 4-SYTE
Systems-Thielsch Engineering, Inc.
Sunday A. Barbaro is Senior Develop-
ment and Marketing Specialist, Thielsch
Engineering, Inc.
assessments for their facilities. Addition-
ally, insurance companies are increasing-
ly requiring inspection and maintenance
records and new EPA regulations have be-
come a major issue within the industry.
The solution to reducing the forced
outage rate of a unit involves taking a
comprehensive approach to boiler man-
agement utilizing unit specifc operation-
al training, advanced data management
and strategic inspection, maintenance,
and replacement prioritization. Based
on over 18,000 custom inspections and
reports, Thielsch Engineering, Inc. has
developed a 3-Step process to improve
boiler reliability and life expectancy that
ultimately reduces costs associated with
scheduled and unscheduled outages.
A UNIT SPECIFIC STRATEGY
Each boiler has its own unique op-
erational history and conditions. To im-
prove a boilers reliability, its imperative
to consider the boilers unique conditions
to develop a strategic plan to improve
safety and reliability. Many plant manag-
ers and engineers never get started with
a reliability program because the task is
so challenging. This integrated three-step
process includes a System Review, His-
torical Review and Budget Review. Each
step has multiple key components that
must be considered when implementing
a proven unit specifc strategy.
PROCESS STEP 1
- System Review Key Components
AGE OF THE UNIT
Facilities built in the 1960s and 70s
experience damage related to the obvi-
ous number of hours of operation; how-
ever they were designed with heavier wall
thickness in both tubing and header com-
ponents. As a result, these units tend to
have longer life expectancies than some
of the newer facilities. Facilities that were
built in the 1980s pushed the limits with
the do more with less approach. Tubing
and headers were supplied with thinner
walled components, conserving costs on
construction, but ultimately reducing the
service life of the critical components.
Modern facilities are being constructed
to adapt to the thermal cycling that has
become a part of the energy culture of
today and are experiencing earlier than
expected failures. Many of these failures
are the result of exotic materials that are
being used which have not been in ser-
vice long enough to know the true behav-
ior of the material under the thermal and
mechanical stresses of cycling a unit.
DESIGN OF THE UNIT
Some boiler units clearly have inher-
ent design faws. Various design faws
include the placement of the burners in
the furnace, how the tubing/headers are
supported and/or the use of water guns or
soot blowers. Understanding the inherent
design faws of a specifc unit will help a
B
oiler tube failures remain
a leading cause of lost
availability in power boil-
ers. The need for strategic
planning with regard to
inspections, preventative maintenance
and targeted replacements is great. Iden-
tifying where and how to begin a boiler
management program can be viewed as
an insurmountable obstacle for many
utility operators and owners. In addition,
the cookie-cutter approach established
in many cases results in poor reliability
improvement due to specifc operating
and design conditions not identifed and
evaluated.
The challenges in reducing a units
forced outage rate include reductions
in the plants engineering staff, an ag-
ing workforce, and the need to remain
competitive. Plant managers are rou-
tinely faced with the daunting task of
determining the current condition of
their equipment, forecasting outage bud-
gets and schedules, and performing risk
Improving
Boiler Reliability
BY PAMELA SMOSKE AND SUNDAY A. BARBARO, THIELSCH ENGINEERING
Implementing a Unit Specifc Strategy
A metallurgical tube sample section representing dissimilar metal weld joint of
stainless steel material to lower-alloy steel material. It is at this type of weld loca-
tion that many failures occur as a result of the temperature induced stress, carbon
diffusion and oxidation resistance. Photo courtesy of Thielsch Engineering
1304pe_26 26 4/4/13 9:17 AM
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PROGRAMS
CUI Management
Tank Maintenance
Thermal Protection
Refractory
Corrosion Engineering
Coatings
Energy Conservation
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BRAND COMPANIES:
1304pe_27 27 4/4/13 9:17 AM
www.power-eng.com
28
1
Stages of Creep Development.
As creep stages progress, the voids begin to link with one another, developing into
cracks whichthen propagate through the material, eventually causing leaks or failures.
H
e
a
d
e
r
,

P
i
p
e

o
r

T
u
b
e

E
x
p
a
n
s
i
o
n

%
Time of Operation
Primary
Creep
Secondary
Creep
Tertiary
Creep
Voids
Linkage
of Voids
Initial
Extension
Microcracks
Major
Cracks
Cracking
Cracks With
Progression
End
of Life
Leaks
which the Code allowable stresses are
based. In such cases the premature failure
of such components is a reality. Addition-
ally, softening of the material resulting
in lower creep strength and can initiate
type IV cracking of the material. It is par-
amount that the use of this material be
frmly understood.
CODE CASE MATERIALS
In the event there is an urgent need for
alternative rules concerning materials,
construction or in-service inspection ac-
tivities not covered by existing Boiler and
Pressure Vessel Code rules, or for early
implementation of an approved Code re-
vision, ASME may issue a Code Case. The
use of Code Case materials are now being
used extensively in superheaters and re-
heaters, specifcally in new HRSGs. Many
of these materials are an enhancement of
2.25 Cr-1 Mo steel to gain additional high
temperature strength. Thielsch Engineer-
ing, Inc. is currently working with several
plants that are or have experienced criti-
cal failures due to the use of such code
case materials. Identifying where and
how these materials are being used in a
unit can greatly affect the ability to pre-
vent premature tube failures.
DISSIMILAR WELDS
Designers of boiler Superheater/Re-
heater pendents incorporate the favorable
mechanical properties of stainless steel
within these sections of the boiler that
combine high heat and high gas fows.
However, due to the high material costs,
these sections are ultimately welded to
more common low alloy steels. The re-
sulting dissimilar metal welds (DMWs)
have a tendency to suffer service related
deteriorations (cracking) over time.
Cracking of dissimilar metal welds is
typically attributed to three primary fac-
tors. The most signifcant factor is the
difference between the thermal coeff-
cient of expansion of the weld deposit
and tubing. This difference results in a
signifcant temperature-induced stress at
the weld interface.
The second factor contributing to the
company become proactive in their ap-
proach to preventative maintenance and
ascertain areas to target for remaining
useful life determinations.
MATERIALS
The American Society of Mechanical
Engineers (ASME) has approved certain
steel materials for use as tubes in boilers
designed according to the ASME Boiler
and Pressure Vessel (B&PV) Code. Sec-
tion I of the ASME B&PV Code specifes
allowable materials in Paragraph PG-9.
Other materials have also been approved
by specifc Code Cases. Understanding
the materials specifc to a unit and recog-
nizing the inherent concerns of those ma-
terials (weldability, resistance to elevated
temperatures and pressure, heat transfer
ability) will enable facilities to be more
progressive in their pursuit to preventing
service related damage.
UNDERSTANDING P91/T91
The use of modifed 9Cr (grade 91)
steel in modern power plants is derived
from the superior properties of the ma-
terial in comparison to carbon steels or
lower chrome materials. It boasts supe-
rior creep and tensile strength charac-
teristics, which allow thinner materials
to be designed into piping systems, pres-
sure vessels and tubing. These are envi-
able characteristics in terms of thermal
cycling, hence the wide spread use of the
material in newer combined cycle plants.
There are some critical drawbacks to
this material that have been realized over
its relatively short lifetime. It provides sig-
nifcant feld welding challenges in terms
of backing, preheat, and post weld, heat
treat programs. There is little margin for
error when welding and/or heat treating
this material. Unlike carbon and low-al-
loy steels, the elevated creep strength in
9-Cr material depends on achieving and
maintaining a specifc microstructure.
Any event during manufacture, erec-
tion or operation that disrupts this mi-
crostructure will compromise the integ-
rity of the material and prevent it from
achieving the creep properties upon
1304pe_28 28 4/4/13 9:17 AM
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30
Metallurgical samples representing several signifcant failure mechanisms
affecting tubing in the utility industry. Identifying the root cause of the failure
is paramount to comprehensively reducing future forced outages.
2
Water-Side Corrosion,
Fire-Side
Corrosion
Tube Erosion
Mechanical
Fatigue
Intergranular Short Term Overheat
PROCESS STEP 2
- Historical Review Key Components
FAILURE/LEAK LOCATIONS
The ability to identify and track the
locations of a tube failure and its root
cause is essential to comprehensively
reducing forced outages. Once the root
cause of the failure is properly identi-
fed, a long term plan can be imple-
mented to ensure the failures/leaks
have been rectifed. Proper and current
documentation is critical to managing
failures and leaks and can be done in
real-time with the use of a data man-
agement program such as the 4-SYTE
System Strategy.
FAILURE/LEAK MECHANISMS
Since boiler tube failures have been
the subject of immense concern to util-
ity companies and boiler manufactur-
ers, there is a tremendous amount of
reports, theories, studies, factual and
unfactual communications and inves-
tigations concerning the different fail-
ure modes and mechanisms. The sig-
nifcant failure mechanisms seen most
commonly in the industry have been
identifed by six broad classifcations:
Stress Rupture
Water-Side Corrosion
Fire-Side Corrosion
Erosion
Fatigue
Lack of Quality Control
The most likely failure mechanisms
can occur in waterwall, economizer
and superheater or reheater tube cir-
cuits. Only those mechanisms listed
for that specifc location need be con-
sidered during a failure incident when
time is essential.
Primary failure mechanisms are the
processes that degrade the tube and pro-
duce a failure. Each failure mechanism
may include several circumstances such
as poor fuel quality, equipment mal-
function or improper operation. Each
would be considered a root cause since
they have created the conditions for a
failure mechanism to exist. Verifcation
of the root cause is a vital activity in a
degradation of this type of weld is carbon
diffusion. This diffusion occurs slightly
during welding and more extensively
during subsequent use in high-tempera-
ture service.
The resulting band of carbon depleted
low-alloy steel immediately adjacent to
the weld interface has a greater propen-
sity for failure due to creep.
The third factor affecting the integrity
of this type of weld is a difference in oxi-
dation resistance between low alloy and
stainless steels.
This difference results in an oxide
wedge forming along the outside and in-
side diameters of the component in ques-
tion at the interlace between these two
materials.
These wedges will continue to grow as
a result of the difference in the oxidation
resistance of the two materials.
The oxide wedges reduce the available
cross-sectional thickness of the compo-
nent, and thus its load bearing capacity.
DMWs must be identifed and included
in your unit specifc plan.
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www.power-eng.com
32
restrictions and temperature excursions
etc. Additionally, as part of the clean air
initiatives currently underway, many
units are being modifed to burn alterna-
tive fuels. Recognizing what modifca-
tions have transpired in a specifc unit
can lend perspective into potential side
effects which may be occurring as a result
of those modifcations.
REPLACEMENTS
As an aging plant begins to experi-
ence repeated failures, sections of tub-
ing and other critical components will
require replacement. These replaced
sections will have fewer hours of op-
eration and therefore will not need to
be considered for inspection on the
same schedule as original equipment
within the unit. This observation is
particularly unit specifc and is a major
basis for why a cookie-cutter approach
to inspection/maintenance is ineffec-
tive and can lead to squandering of
precious budget funding inspecting
equipment that has not yet reached a
point in its life cycle to require exami-
nation.
OPERATIONAL CHANGES
Most power generation facilities were
designed on the assumption that they
would be operated in a base-load mode
or infrequently cycled. However, in re-
sponse to local power market conditions
and the terms of their power purchase
agreements, many plants are now cycling
their units more frequently than design-
ers had intended. This results in greater
thermal stresses, more pressure cycles,
and therefore more cyclic fatigue damage
and overall faster wear and degradation
to the critical components due to both
the mechanical and corrosion processes.
As a general comment, cycling service
has an adverse effect on the life expec-
tancy of a unit. This is due to the fact
that cycling results in fatigue loading
(alternating cyclic stresses); whereas base
load operation results in creep (sustained
stresses). Depending on the severity of
the stresses, and the number of cycles, fa-
tigue loading can result in cracking, par-
ticularly at restraint locations.
UPSET CONDITIONS
When a unit trips and is brought of-
fine suddenly or experiences a water
hammer event, an immense amount of
thermal and mechanical fatigue can be
introduced to the involved components.
It is benefcial to understand if a unit
has experienced any major upsets dur-
ing its life cycle in order to determine if
evaluating areas that wouldnt normal-
ly come under the microscope is nec-
essary. This is similarly unit specifc
and would be comparable to the con-
siderations you would evaluate if you
were purchasing a used car. Just as the
purchaser would investigate any past
maintenance troubles or collisions of
the vehicle prior to purchasing, plant
managers must consider the history of
their units prior to determining the in-
spection prioritization of their critical
components.
failure investigation and is necessary to
assure the correction of a failure problem.
Secondary failure mechanisms such as
adjacent tube washing or adjacent tube
impact can produce a tube failure and are
always a concern after an initial failure.
Our experts at Thielsch Engineering, Inc.
refer to this as collateral damage. Of-
ten times following a forced outage as a
result of a tube failure, there is such an
urgency to return a unit to service, that
identifying areas of collateral damage
are overlooked. Consequently, the unit
is forced offine again as the result of
additional tube failures in these collat-
eral damage locations.
MODIFICATIONS
On occasion inherent defciencies of
a unit design will be identifed. As a re-
sult, the unit may undergo design modi-
fcations which can resolve the original
design faw concerns, but ultimately can
create other issues such as steam fow
1304pe_32 32 4/4/13 9:17 AM
www.power-eng.com
3 Area Failure Summary By %
Rear Waterwall
Cyclones
Rear Waterwall
Panel Assembly
Primary
Superheater Assembly
Secondary Superheater
Inlet Assembly
Secondary Superheater
Outlet Assembly
Front Outlet
Header
Inlet Header
Outlet Header
Inlet Assemblies
Outlet Assemblies
Front Waterwall
Front Waterwall
Cyclones
Left Waterwall Assembly
Right Waterwall Assembly
Rear WaterwallAssembly
16%
3%
3%
3%
3%
6%
3%
3%
3%
3%
3%
3%
3%
3%
22%
13 %
6%
Reheat Inlet Section
Reheat Outlet Section
cut your losses and replace sections
will improve reliability. Many factors
can affect the life expectancy of key
components in a boiler including wa-
ter chemistry, fuel type and quality,
thermal cycles, materials, temperature
excursions, inadequate heat transfer
and fow rate. Understanding key fac-
tors associated with a specifc unit that
can ultimately contribute to shorten-
ing the life expectancy is paramount
to predicting remaining useful life of
critical components.
PRIORITIZATION: INSPECTION,
REPAIRS, REPLACEMENT
The ability (and necessity) to develop a
plan of action that includes prioritization
for inspection, repairs and/or replace-
ments established from the unit specifc
design and historical operation will dra-
matically improve the budgetary process.
Allotted funds will be used in an effective
manner and outage planners will have
the ability to provide back-up docu-
mentation required to warrant the neces-
sity for such funding during the company
fscal budget planning process.
OPERATIONAL TRAINING
Many times the operators of units are
responding to directives from a senior au-
thority to bring the unit online or offine
to meet the load requirements and capac-
ity. Understanding the effects of ramping
constraints in both unit commitment
and economic dispatch is imperative.
Operators can have a tremendous effect
on the life expectancy of a unit simply by
recognizing the effects of proper ramp
rate execution. Operators have direct con-
trol of the temperature of the unit; there-
fore proper unit specifc training can add
years to the life of the unit.
PROCESS STEP 3
- Budget Review Key Components
REMAINING USEFUL
LIFE DETERMINATIONS
Determining the remaining use-
ful life of critical components/tubing
will allow for proper budgeting for re-
placements. Additionally, as systems
begin to reach the end of their life
cycle, more failures will inevitably be-
gin to occur. Understanding when to
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EPA REGULATIONS
EPA regulations change constantly
and facilities are faced with having to
upgrade emissions or retroft to meet
these EPA regulations. Funding that
would have otherwise been used for
maintenance and inspection or re-
placements are then reallocated.
A comprehensive unit specifc stra-
tegic plan combined with a data man-
agement program will assist in early
detection of a units remaining use-
ful life cycle and/or identify solutions
that could potentially void the need to
decommission or upgrade. More and
more facilities are being decommis-
sioned rather than upgrading because
the cost of performing the needed
modifcations outweigh the proftabil-
ity of the units potential output.
SAFETY AND RISK MANAGEMENT
Safety and risk management are
highly regulated and are vital to a fa-
cilities success. A comprehensive pro-
gram that focusses on operator train-
ing, maintenance and testing, as well
as replacing components that have
reached the end of their useful life
can reduce the risk of component fail-
ures within a power boiler. The need
to create this custom plan is essential
to the overall operation of the facility
and most importantly the safety of the
workers. Additionally, a progressive
data management plan can offer ex-
tensive reductions in insurance costs
as this establishes a proactive philoso-
phy to prevent catastrophic events.
PROVEN SOLUTIONS
Every producing facility must have
a system to better manage overall op-
erations and the use of a data man-
agement plan that offers control and
real-time solutions from anywhere in
the world. The combined process of in-
tegrated engineering that includes unit
specifc education, observation, track-
ing, proper maintenance and data col-
lection provides a modern approach
to a complex and highly competitive
market.
OUTAGE SCHEDULES
Facilities typically have an outage
schedule to provide regularly scheduled
maintenance and inspection of major
components. Short outages typically oc-
cur once a year and last about 7-10 days.
Major outages typically occur every two-
three years and last in upwards of 3-6
weeks depending on if replacements are
scheduled or major overhauls of equip-
ment are required. Developing a plan of
action and having an understanding of
when and why these outages are sched-
uled can help allocate funding for priori-
tization of inspections and maintenance.
For example, if a plant is experiencing
tube leaks, but arent scheduled for a ma-
jor outage for another year, it may elect
to do a quick fx or band aid type of
repair to continue operations until the
major outage. It is paramount that the
problem be properly analyzed to ensure
that the temporary method to hold will
be effective. This determination requires
experience, expertise and documenta-
tion of the components in question. All
of this can be obtained by utilizing a unit
specifc strategic plan with a custom data
management program.
BUDGETARY ALLOCATION
Alas, the budget. A common frustra-
tion among plant managers and plan-
ners occurs once the hurdles associ-
ated with identifying what needs to be
done has been achieved; yet securing
the appropriate funds becomes a chal-
lenge. Planners must justify the prior-
ity for the proposed funds and with
that, clear documentation and profes-
sional support is essential.
Once the requested funds have been
allocated, it must be utilized in the
most effective manner with a clear
plan of action. A unit specifc plan and
a real time management plan will not
only maximize the return, but also
improve overall safety and reliability.
Budgets can be justifed when the sys-
tem review and historical data have
been retained and readily available by
way of a data management program.
1304pe_35 35 4/4/13 9:17 AM
www.power-eng.com
36
emissions can be reduced without hav-
ing to break the bank, and some of
those systems either expand on avail-
able technologies or are new, innova-
tive designs.
IMPROVING ON EXISTING
TECHNOLOGIES
The Electric Power Research Institute
(EPRI) is researching technologies to low-
er the capital and operating costs of con-
trolling mercury and improve effciency.
EPRIs research efforts apply to both new
and existing technologies.
EPRI is working to improve existing
controls and determine how to handle
challenging applications, such as high-
sulfur coal or cycling issues during op-
erations, said Tony Facchiano, senior pro-
gram manager of EPRIs Environmental
Controls program area.
EPRI wants to fnd controls that are po-
tentially more cost effective, effcient and
multi-pollutant since more regulations
requiring fewer pollutants are expected.
One thing EPRI is looking into is improv-
ing sorbents.
Were fnding ways to make them
more effcient and more tolerant to fue
gas, said Ramsay Chang, technology ex-
ecutive of the Integrated Environmental
Controls program with EPRI. Sorbent
technology is taking incremental steps to
get better and be more usable.
Chang said the group also is looking
into how emission controls would impact
the balance of plant and how bromine
could affect other parts of the plant.
The biggest issue people worry about
is bromine, Chang said. When you add
bromine to the boiler, you get bromine
activated carbon. Although we do not see
big problems now, we want to make sure
theres no unexpected corrosion or leech-
ing on other metals.
The third issue is cost. EPRI is investi-
gating ways to lower the cost of emission
controls, including activated carbon in-
jection (ACI). and taking a look at tech-
nologies that are off the beaten path,
Chang said.
Were working with Gore to look at
technology that is almost membrane-
like. Its not something you would nor-
mally see, Chang said.
Gores sorbent polymer composite
modules would be placed in the fue gas
path, and the carbon granules would
adsorb mercury and oxidize SO
2
to SO
3
.
The composite material would be made
out of activated carbon granules em-
bedded in a Tefon polymer matrix and
formed into sheets.
EPRIs Facchiano said the organization
W
ith a slew of
rules from the
U.S. Environ-
mental Protec-
tion Agency in
effect, under review or being rewritten,
power producers are looking for ways
to reduce emissions of mercury and
other pollutants, either by installing
emissions controls, switching to low-
sulfur coal or converting coal-fred
equipment to burn natural gas. There
are many ways in which mercury
Whats New
or Improved in
Mercury Controls?
BY SHARRYN DOTSON, ONLINE EDITOR
A wet FGD with Gores SPC
modules placed above
the mist eliminator. Photo
Courtesy of EPRI
1304pe_36 36 4/4/13 9:19 AM
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www.power-eng.com
38
whether or not any additional equip-
ment will be necessary, what the impact
is of combining SO
2
sorbent injection
with ACI, what removals can be expect-
ed with a fuel switch, or whether or not
the fy ash will remain salable for use in
Portland cement, Pealer said.
Carbon testing can be done before in-
stalling an ACI system to help a utility
more accurately determine how big or
small the system should be, Pealer said.
Testing can also help utilities in other
money-saving ways.
The testing may also show whether
or not additional technologies will be
necessary such as dry sorbent injection
for SO
3
control, or a baghouse installa-
tion for better contact between the mer-
cury and the carbon, Pealer said. For
those units that have wet scrubbers, car-
bon testing can help a utility decide if
they prefer to remove the mercury in the
particulate capture device along with the
ash, or with the wet scrubber, or some
combination of the two.
Calgon Carbon offers a product line
of carbon testers called FLUEPAC. The
line includes standard grade activated
carbon, and the products have been
proven to reduce the amount of acti-
vated carbon injected by 50-70 percent,
while still meeting the same mercury re-
duction rates, Pealer said.
There are many other ways to measure
the mercury in the fue gas, including
semi-continuous monitoring systems
(Hg-CEMS), carbon traps and the On-
tario Hydro Method, which determines
the amount of elemental, oxidized, par-
ticle-bound and total mercury emissions
from stationary coal-fred sources, such
as power plants.
MERCURY CONTROLS
ALREADY AVAILABLE IN
THE MARKET.
Norit, based in Marshall, Texas, of-
fers powdered activated carbon (PAC)
products for mercury and dioxin emis-
sion control, and was the frst company
to start using activated carbon for mer-
cury control in the 1980s, according to
the company website. The company also
created storage silos and dust-free dos-
ing units specifcally designed for fue
gas treatment, long-term reliability, low
maintenance and ease of operation.
The companys latest PAC technology is
the Darco Hg-LH Extra, which is a premi-
um impregnated sorbent that is designed
to improve oxidative capability resulting
in improved mercury adsorption kinet-
ics. It is a free-fowing powdered carbon
with minimal caking tendencies, which
is good for automatic dosing systems.
Another company, Albemarle, also of-
fers PAC products, along with calcium
bromide and a second generation car-
bon injection system called the M-PACT.
Services provided include plant analysis,
mercury mitigation demonstrations (of
which Albemarle has performed more
than 90), and project management, mak-
ing them a one-stop shop for clients look-
ing to control mercury emissions.
Like many companies, Albemarle
customizes mercury control solutions
depending on the clients needs. They
take into consideration fuel composi-
tion, fue gas composition, the sale of
byproducts and confguration of fue
gas fow path from economizer to
stack, among other things.
Albemarle also has a pilot scale, duct
injection unit (DIU) at its Process Devel-
opment Center in Baton Rouge, La. The
DIU simulates boiler conditions and al-
lows powdered reagents to be injected
into a fowing gas stream, allowing re-
searchers to approximate the perfor-
mance of different products before any
feldwork is done.
All of the manufacturers and research-
ers agree that complying with federal reg-
ulations may seem daunting at frst, but it
can be achieved without companys bud-
gets taking a major hit. The key is fnding
the right system to work with your power
plant and meet your emission control
goals.
is also looking into ways that mercury
controls can be run while providing co-
benefts for other pollutant controls.
Were looking at how polishing tech-
nology can work with upstream tech-
nology, Facchiano said. These would
be incremental improvements that can
be used as a stand alone or in a series.
Chang said researchers are looking
at what can be retrofttable. Not just
polishing, but something you can put
in a power plant without major recon-
struction.
Chang said he thinks these improved
systems could be commercially avail-
able within the next one to fve years,
but that depends on the type of applica-
tion being used.
The reason for the timeframe is be-
cause utilities have to comply by 2015,
so they need to have things in place
by then, Chang said. Just to comply
with the deadline, you continue to push
technology to the next phase in differ-
ent situations, but with the timing, we
cant wait.
Facchiano said that has to do with
capital costs versus operating costs.
With activated carbon, there may be
ways to produce it that are more cost ef-
fcient. If one has already installed the
system, the primary cost is the cost of
the carbon itself.
CARBON TESTING
Another method used in mercury
control is activated carbon testing,
which verifes the amount of mercury
removal from fue gas at a point down-
stream of the injection. The injection of
the carbon can be carried out with a full-
scale activated carbon injection system
or with a temporary injection skid and
super sack loader.
Michael Pealer, marketing man-
ager Mercury Removal with Calgon
Carbon Corp., says carbon testing can
be used for several purposes besides
emissions control.
A utility may want to determine
1304pe_38 38 4/4/13 9:19 AM
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www.power-eng.com
40
the benefts and challenges associated
with alliance contracts.
What follows is a transcript, edited for
style and length, of that discussion:
POWER ENGINEERING: What are
the advantages of having an alli-
ance contract versus doing the work
yourself or contracted piecemeal?
BRIDSON: We see more consistency
among our feet. Its better than having
different contractors working at different
power plants. It also
helps us execute con-
sistent processes and
practices in our orga-
nization.
I can tell you a short
story. We were facing a
deadline on a particu-
lar project. It was an
environmental project, so it had a dead-
line on it, but it was a pretty short time
frame. Since we had our alliance con-
tractor (Day & Zimmermann) on board,
what we were able to do was work with
them, while the engineering was still
going on, to perform constructability
reviews. They actually had input in the
engineering. We were able to go ahead
and develop timely estimates. We were
able to execute the project both on time
and on budget. If we didnt have that al-
liance partner, things would have been
a lot more diffcult because the time
frame was not con-
ducive to getting the
engineering done,
putting a bid scope
together for the in-
stallation and then
going out for bids.
Having a trusted
partner made us com-
fortable to move forward on the project,
which was very successful.
A
s power producers face
declining sales growth
and hefty costs for
new emission controls,
tools for improving ef-
fciency and lowering operating costs
are paramount for utilities with large
generation assets.
One option allows power producers
to outsource their maintenance and
outage services to third parties. These
third-party agreements are known as
alliance contracts, a unique long-term
arrangement designed to help utilities
achieve their goals for safety, quality,
availability and outage rates at a low
cost. They are complex pay-for-perfor-
mance agreements that incentivize the
service provider.
Power Engineering explored the struc-
ture, makeup and rationale behind these
contracts in an interview with executives
of Westar Energy and Day & Zimmer-
mann NPS. D&Z is one of the nations
leading power plant maintenance and
modifcations contractors. Westar Energy
is the largest electric utility in Kansas,
with 7,000 MW of generation capacity
and nearly 700,000 customers.
John Bridson, Westars vice president
of Generation, and Paul Williams, vice
president of Operations for D&Z, sat
down with Power Engineering to discuss
OPERATIONS & MAINTENANCE
Reaping the Benefts
of Alliance Contracts
Executives from Westar Energy and Day & Zimmermann NPS discuss
the value of alliance contracts and long-term maintenance agreements.
The Jeffrey Energy Center, a 1,857-MW coal-fred plant in St. Marys, Kan., is one of several
plants maintained by Day & Zimmermann NPS under a long-term maintenance agreement
with Westar Energy. The agreement known as an alliance contract is a complex pay-for-
performance agreement designed to lower utilities costs and improve effciency.
You have to be
careful about the
partner you pick.Its
kind of like entering
a marriage.
- John Bridson, Westar
1304pe_40 40 4/4/13 9:19 AM
www.power-eng.com
41
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42
of framework for resolving conficts.
WILLIAMS: When I meet with compa-
nies that arent using alliances, I talk a lot
about the need to establish governance.
John and I provide governance and are
in lockstep as to our expectations for our
teams. We regularly have discussions
about that. Alliance contracts seem to
be onerous to both sides in the begin-
ning because of the need for a culture
change. They work best when you have
a formal change-of-management plan. If
youre going to be an alliance contractor,
you have to see yourself as the brother-
in-law sleeping on the couch. You better
add value every day if you want to have
a place to stay.
POWER ENGINEERING: Can you
describe the scope of your alliance
agreement with D&Z?
BRIDSON: For us, D&Z provides
union craft labor primarily in boiler
maintenance and construction activi-
ties. But they also have a core staff of
both craft and management that is with
us all of the time. Those folks perform
ongoing work and respond to forced out-
ages. They also provide us project man-
agement, project controls, quality con-
trols, safety supervision and training for
the work theyre involved with. For some
of our small plants, they will provide the
overall outage schedule, which includes
work theyre not performing and po-
tentially even work performed by other
contractors. They truly are a partner in
every sense of the word.
POWER ENGINEERING: Can you
describe the contract terms and
how Westar evaluates D&Zs per-
formance?
BRIDSON: Its pay for performance.
You might even call it a Fee-at-Risk
Contract. We defne certain goal the
alliance needs to meet. Some of those
goals are the exact same ones that our
management staff is working toward -
things like plant reliability and coming
in on budget. We then turn that into
a scorecard, which we evaluate twice a
year after each outage season. We score
D&Z in about nine key categories,
including safety. If we fnd things that
we want to work on, well put those
on the scorecard. Occasionally, well
modify the scorecard. Well take some
things off where weve achieved what
we wanted to achieve and well add
something new. Then we mutually
agree on the outcomes of that score.
D&Z has an opportunity to argue with
us. Sometimes they can convince us to
change the score.
WILLIAMS: We develop scorecards
to measure our performance and place
our fee at risk to demonstrate value.
WILLIAMS: The alliance model pro-
vides the optimum environment for us
to work with the customer. It provides
safe, quality services at the lowest cost.
Johns organization allows us to have a
seat at the table with his team. We regu-
larly share ideas and come up with the
best solutions together.
We establish what we call Key Per-
formance Indicators (KPI) or pay-for-
performance measures. These measures
help improve the process and the work
product. We adjust them to continue to
better meet business needs. My favorite
part about the KPI contracts is it allows
us to have a laser focus on what we need
to work on to improve.
POWER ENGINEERING: What
should a utility consider before
entering a long-term alliance con-
tract?
BRIDSON: You have to be real careful
about the partner you pick. Its kind of
like entering a marriage. You dont want
to do this very often. You just want to
do it once and hopefully be done with
it. The companies need to have a shared
value system and the cultures need to
complement each other. That doesnt
mean its always rosy every day. With-
out a little bit of confict, youre prob-
ably not sharpening your saw and get-
ting better. We enjoy our relationship
with D&Z. We challenge each other and
we work to get better.
I think you also need to defne up
front what the goals of the relationship
are. You have to defne the parameters
around working toward that shared
goal. You also have to provide some kind
John Bridson Paul Williams
The pay for
performance model
incents us to fnd a
better and safer way
to do work that saves
the utility money.
- Paul Williams, D&Z
1304pe_42 42 4/4/13 9:19 AM
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The reason the scorecard is important is because if you
cant measure it, you cant improve it. When youre able to
measure the results, it gives you the information needed
to take corrective actions as required and to demonstrate
success to the organization.
POWER ENGINEERING: Can you quantify the sav-
ings youve recognized under your alliance contract
with D&Z? How does the cost of O&M compare to
the cost you would have incurred had you done the
work yourself?
BRIDSON: Its diffcult to quantify cost savings because
we may have not always been doing the things we do with
D&Z in the past. What I can tell you are a couple of stories.
Westar has seen a huge improvement in boiler reliabil-
ity. In fact, weve doubled the mean time between failures
for boiler tube leaks since we started our alliance contract
with D&Z. Weve basically cut the rate of tube leaks in
half. D&Z has been a huge part of that. They have helped
us improve our planning process. I think they have good
quality controls. We have very few rework issues. Good re-
liability on our lowest-cost coal units probably saves our
customers millions of dollars in fuel every year.
WILLIAMS: We are always able to estimate the work and
make a commitment to how long we think its going to
take. Anytime you do that, you gain worker utilization
because you are able to build and work a plan, working
a plan is the safest place for our people and the most
productive. In this model, we have to predict what were
going to do. We have to strive to reduce the cost of the
next evolution and any additional evolutions of the same
work. The pay-for-performance model incents us to fnd a
better and safer way to do work that ultimately saves the
utility money.
POWER ENGINEERING: What about labor availabil-
ity? Do you have a plan in place to mitigate the im-
pact of labor shortages?
WILLIAMS: John and his team have afforded us
the opportunity to establish what we call a tri-lateral
organization established to bring together local labor,
Westar and D&Z. We regularly sit down at the table with
those folks and talk about safety, labor requirements
and needed skill sets. We know our work scopes well in
advance, which allows us to be the frst on the spot with
the local building trades to put our requisitions in and
project what were going to need. We have worked with
local building trades around the country and at Westar
to survey labor availability and to project future craft
requirements.
1304pe_43 43 4/4/13 9:19 AM
www.power-eng.com
44
Electrical Manufacturers Associations
Executive Committee and the Business
Round Table.
Santacana recently sat down for an
interview with Power Engineering to
discuss the future of power generation
in North America and efforts to expand
the Demand Response industry,
which is the business of creating
capacity through the use of smart grid
technologies.
His comments, edited for style and
length, follow:
POWER ENGINEERING: How
would you describe the market for
power generation technologies
that help utilities improve effcien-
cy, produce cleaner power and
lower emissions? What types of
products and services interest your
customers the most?
SANTACANA: We provide major
product portfolios to the power genera-
tion industry. One is within the category
of process control. There we have distri-
bution control systems. The newer ver-
sions are very powerful, being able to
collect data from thousands of devices
throughout the power plant. We can
turn that data into actionable informa-
tion, apply some very sophisticated al-
gorithms to that information and then
turn that into operational decisions.
Those decisions are then communicated
back to critical equipment throughout
the power plant in order to optimize
their performance. Control technologies
are a major strength of ABB.
The other area where we provide
arguably the largest product range in
the industry is in instrumentation.
We provide very accurate measure-
ment equipment. These products pro-
vide critical information for the power
plant operator to optimize the process.
Instrumentation has been a good
source of business for us over the last
three years.
Those are the two areas inside the
power plant where we can make a ma-
jor difference.
POWER ENGINEERING: For many
utilities, the growth rate of electric-
ity sales has dropped to less than
1 percent a year. What can they
do to mitigate the economic effect
of this trend? Can an effective De-
mand Response program make a
meaningful difference?
SANTACANA: First and foremost,
utilities have to increase the rate of
productivity improvement to deal
with the slowdown in sales growth.
Thats the best way they can keep their
margins at the same level or grow
their margins. In terms of increasing
productivity, the most important way
to get there is improving operational
effciency. What we see our customers
doing and what we are helping them
T
he pursuit for greater ef-
fciency is escalating as
power producers face di-
minishing sales growth
and more costly envi-
ronmental regulation. A central voice
in this revolution belongs to Enrique
Santacana, a business-savvy electri-
cal engineer who leads one of North
Americas top suppliers of power and
automation technologies.
Santacana, president and chief execu-
tive of ABB Inc. and head of the com-
panys North America operations, was
appointed to his present position in July
2007. Hes become an infuential fgure
in Americas efforts to improve Demand
Response capabilities and optimize Vir-
tual Power Plant technologies.
The ABB Group has a presence in
about 100 countries and employs more
than 145,000 people. The companys
North American operation, headquar-
tered in Cary, N.C., employs about
30,000 people in facilities across the
U.S. and Canada.
Santacana is an engineer with a
bachelors degree from the University
of Puerto Rico, a masters degree from
Rensselaer Polytechnic Institute and a
masters of business from Duke Uni-
versity. He joined ABB in 1977 and
held a number of key leadership posi-
tions within the company, including-
President of Power Products Division
in North America. In 2008, he was
appointed to the U.S. Department of
Energys Electricity Advisory Commit-
tee. He is also a member of National
The Path to
Greater Effciency
A Conversation with ABBs Enrique Santacana
Enrique Santacana,
Chief Executive of ABB Inc. & Head
of North America Operations
1304pe_44 44 4/4/13 9:19 AM
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www.power-eng.com
46
level of service. This is helping them
reduce costs. On the fxed asset side,
you have asset health technology,
which is a way to manage the life cycle
of their most important fxed assets
with prioritization, allocation and
deployment of maintenance. It also
helps them decide when is the best
time to retire an asset or bring a new
one online.
There is another area that is impor-
tant for utilities in a time like this.
Utilities need to do a better job of edu-
cating their regulators. The return on
their investment should not depend
completely on selling more kilowatt
hours. There has to be an incentive for
utilities to save kilowatt hours. Until
the present business model is changed,
there will be a disconnect between
everybody talking about energy eff-
ciency and the need to produce more
kilowatt hours. That somehow has to
be corrected. Thats where Demand Re-
sponse comes in. Demand Response is
about being able to save kilowatt hours
in a way that provides the end user as
well as the supplier with the economic
incentive to be more effcient and to
allocate resources in a more effective
manner. But the incentives have to be
there to move forward.
your customers telling you about
the long-term supply and price of
natural gas in North America? Will
the transition to gas-fred genera-
tion continue in the U.S.?
SANTACANA: Our utility customers
are telling us that there is more natural
gas for a longer period of time at a low-
er cost than ever. Thats a pretty power-
ful combination. That tells you there is
going to be a very signifcant shift from
coal-fred generation and even other
sources to gas. Youre going to have
lower costs because of more availabili-
ty enabled by new extraction technolo-
gies. Youre going to have lower green
house emissions, which you get from
natural gas compared to coal. Then
you have this game-changing shale gas
providing some certainty of supply for
years, if not decades, to come. I dont
see how the shift to natural gas would
not continue.
with is improving the operational
effciency of both their people assets
and their fxed assets. We have a new
mobile workforce technology that
helps utilities prioritize, allocate and
deploy people resources to make
them more effcient and improve the
1304pe_46 46 4/4/13 9:19 AM
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Then you have the new build of gas-
fred generation. All of that represents
an opportunity for us. We believe we
have the most complete electrical
balance of plant product range in the
industry. What that includes is control
and instrumentation technologies.
But in addition to that, we also offer
the electrifcation inside and outside
the fence. Its all about connecting
the power plant to the grid. We have
the transformers, the high voltage
and medium voltage switchgears,
the motors and the drives. We are a
manufacturer of all of those products.
We also have the technologies to
provide grid stability.
We have a complete package of tech-
nologies and products. We want utili-
ties to look at ABB as a one-stop shop.
They need to increase their operational
effciency, but they also need to be look-
ing at how to modernize their power
plants and how to connect more eff-
ciently to the grid. ABB has several di-
visions and business units. This Clean
POWER ENGINEERING: In De-
cember, ABB launched a new pro-
gram for power producers known
as The Clean Air Initiative. Specif-
cally, what kinds of tools does this
program offer to help power pro-
ducers cope with stricter emission
standards and the retirement of
coal-fred power plants in the U.S.?
SANTACANA: The Clean Air
Initiative was borne out of three major
drivers that we see in the marketplace.
We have aging infrastructure. We have
stricter EPA regulations, particularly as
they relate to air emissions. And then
you have, as we just discussed, shale
gas as a game changer. With those
three drivers, we have some outcomes.
We have the outcome of older coal-
fred plants being retired. The newer
coal-fred plants are being retroftted.
Utilities need to
do a better job of
educating their
regulators. The return
on their investment
should not depend
completely on selling
more kilowatt hours.
There has to be an
incentive for utilities to
save kilowatt hours.
Enrique Santacana, ABB
1304pe_48 48 4/4/13 9:19 AM
www.power-eng.com
49
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ergy. On one hand, you have the chal-
lenge to fnd the optimal balance
between costs and environmental im-
pact. That has to be a continuous point
of attention. On the other hand, you
have Demand Response enabling what
we call end-user engagement. This will
facilitate choice for the end user, but
at the same time an affordable choice.
Economic growth is not going to hap-
pen if the cost of electricity spikes and
everybodys costs go up. We must be
able to calibrate the engagement of
the end-user with affordable electric-
ity, the need of utilities to generate a
return for their shareholders and the
imperative to manage costs in a way
that protects the environment. The in-
teraction between these objectives has
to be very well coordinated.
Air Initiative brings a cross-divisional
approach, where we have the people re-
sources that can talk across the entire
spectrum of electrical balance of plant
to power plant operators. They can go
to one point of contact at ABB and can
get the entire solution.
POWER ENGINEERING: What is the
greatest obstacle in advancing the
use of smart grid technology and
demand response programs? Is it
dispatching? Is it an issue of system
management technology?
SANTACANA: The biggest obstacle
utilities are facing in smart grid imple-
mentation is that they are not, by and
large, incentivized to increase reliability,
security and effciency, which is what
the smart grid market is all about. Its a
disconnect between the business model
that says sell as many kilowatt hours as
you can versus the business model of
utilizing assets more effciently. Utilities
are already investing in a smarter grid,
but its not the boom people were ex-
pecting. Thats not going to happen, in
my opinion, in any major way until you
have incentives aligned with reliability,
security and effciency.
your fnal thoughts about the future
of power generation and Demand
Response in North America?
SANTACANA: Power generation
and Demand Response are two very
important elements of the electric-
ity value chain. Going forward, there
has to be a much larger interaction
between Demand Response and pow-
er generation so that we can provide
1304pe_49 49 4/4/13 9:19 AM
www.power-eng.com
50
Author
Brad Buecker is a contributing editor for
Power Engineering and also serves as a
process specialist with Kiewit Power En-
gineers in Lenexa, Kan.
natural gas-fred units. This is a con-
cept that a co-author and I discussed
in a previous issue of Power Engineer-
ing, in which a straightforward heat
recovery technology offers an op-
portunity for combustion turbine
plants to potentially become net
fresh water generators. The technol-
ogy bears a reminder.
Treatment of wastewater streams can
be very complex due to the variety of
impurities that is in the stream with
ever-changing concentration. Lessons
continue to be learned regarding waste-
water treatment, and I will examine
some of these as well. Lets plunge into
the discussion.
What Are We Dealing With?
Fig. 1 shows a snapshot analysis of
lake water from a plant where I formerly
worked.
Only the primary constituents are
shown, but this analysis is revealing in
that even the water from what is a pris-
tine lake that also serves as a recreational
site contains signifcant quantities of the
hardness ions calcium and magnesium;
the basic anions bicarbonate alkalinity,
chloride, and sulfate; and additional im-
purities, including suspended solids and
silica. Other supplies may contain these
and other impurities in much higher con-
centrations. For example, groundwater
supplies where the water has percolated
through limestone often have very high
hardness levels. In the western U.S.,
groundwaters may contain 30 to 50 ppm
silica. Both seasonal and transient weath-
er conditions such as heavy rainfall can
cause enormous fuctuations in surface
water chemistry. Agricultural chemi-
cal runoff can be a signifcant problem
at times in many locations. Gray water
(tertiary-treated sanitary sewage) may
contain noticeable quantities of organics,
ammonia and phosphate.
Cooling towers are wonderful air
scrubbers that easily remove particles
from the incoming air. With the knowl-
edge that cooling towers are being in-
stalled at many new plants to avoid com-
plications from once-through cooling,
lets consider as an example a plant with
a cooling tower operating at fve cycles
of concentration. Simple math says that
all of the constituent concentrations will
increase fvefold. However, a number
of reactions can occur in this cocktail.
Without any scale formation treatment,
calcium and alkalinity will react to pro-
duce calcium carbonate deposits, partic-
ularly in the warmest spots in the cooling
loop, most notably the condenser. Silica
is a very complex constituent and may
form scale on its own, or at elevated pH
P
ower plant owners, op-
erators and technical
personnel continue to be
faced with increasingly
stringent restrictions
regarding the quantity and quality of
plant wastewater streams. Besides con-
cern over the problems wastewater im-
purities can cause when discharged to
a receiving body of water, other factors
that can infuence wastewater and water
recycle issues include:
The diminishing supply of fresh
water for plant makeup, either forc-
ing plants by necessity or through
regulation to use more problem-
atic sources, such as gray water, for
makeup. The ultimate scenario is an
increase in plant construction along
coastal areas, where seawater is lim-
itless in content but highly concen-
trated with impurities.
More cooling tower systems as new
plants are designed to avoid diff-
culties with pending U.S. Environ-
mental Protection Agency regula-
tions 316(a) (thermal discharge) and
316(b) (protection of aquatic crea-
tures from intake dangers) on once-
through systems set to be enforced.
Requirements in some areas of the
country for plants to establish zero
liquid discharge (ZLD). Remov-
ing the last fraction of water from
a waste stream adds much cost and
complexity to a project.
The potential ability to recover wa-
ter from fue gas, particularly from
Wastewater
Minimization:
The Continuing
STORY
BY BRAD BUECKER, CONTRIBUTING EDITOR
Source:
Major Cations (mg/l) Major Anions (mg/l) Other (mg/l)
Calcium 60 Alkalinity 103 Silica 2
Magnesium 12 Chloride 32 Iron 0.1
Potassium 7 Nitrate 0.5 Manganese 0.1
Sodium 32 Sulfate - 77 pH range 7.8-8.5
Snapshot Analysis Of A Midwestern Lake 1
1304pe_50 50 4/4/13 9:19 AM
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2
Generic outline of an emerging
wastewater treatment technology
Permeate
Return to
Process
CT
Blowdown
UF or MF
NaHS0
3
Sodium
Softener
NaOH
High pH
RO Unit
Reject to
Pond or E/C
Now regulations are becoming tighter re-
garding phosphorous discharges because
the chemical induces unwanted algae
blooms in receiving water supplies, and
heavy metal discharge, including zinc, is
being curtailed or even banned. Another
common component of cooling tower
treatment programs is an anionic disper-
sant that keeps the typically very small
negatively charged suspended particles
in cooling water in a suspended state. In
fact, this chemistry underlies
the frst lessons-learned com-
ment later in this article.
Other waste streams also
comprise the total emissions
from power plants. Roof and
foor drains are a notable ex-
ample, and these may contain
oily materials and most def-
nitely will carry suspended
solids. Washdown of plant
components can introduce
similar contaminants to a
waste stream. A common equipment re-
quirement for these streams is an oil/wa-
ter separator. The treated water is blended
with the overall wastewater stream for
further conditioning, while a vendor re-
moves the usually small amount of waste
oil for disposal offsite.
The other major factor that is driving
improved wastewater treatment meth-
ods is water recovery and reuse. Even at
some plants where suffcient fresh water
may combine with cations,
most notably magnesium, to
form magnesium silicate.
Microbiological fouling is
often the single worst prob-
lem that occurs in cooling sys-
tems. To counteract fouling,
scale and corrosion mecha-
nisms in cooling systems, a
variety of treatment programs
is available, but each of these
introduce additional constitu-
ents to the cooling water. For
example, a common cooling tower pro-
gram utilized for years was a blend of
inorganic phosphate, organic phosphates
(commonly known as phosphonates),
a small amount of organic polymer and
perhaps a small concentration of zinc.
In a nutshell, the phosphate and phos-
phonate blend helps control both scaling
and corrosion, the polymer minimizes
calcium phosphate scaling, and the zinc
provides added corrosion protection.
1304pe_51 51 4/4/13 9:19 AM
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Air
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HRVG
C T
Exhaust
A sodium softener to remove cal-
cium and magnesium.
Sodium hydroxide injection to
elevate the pH to more than 10.
(The combination of hardness
removal and pH elevation keeps
silica in solution.)
Two-pass reverse osmosis (RO)
treatment to recover 90 percent of
the water.
As is evident, two streams emerge
from this process. Lets consider the RO
permeate frst. A two-pass system can
is available, regulations require limited
fresh water withdrawal, so wastewater
treatment must produce a recyclable
product for return to the process.
WASTEWATER REDUCTION
The frst step in a wastewater reduc-
tion program is to remove and recover
the bulk of the water as economically
as possible, leaving only a small stream
for treatment by more costly methods. A
rapidly emerging technology, as shown
generically, is outlined in Fig. 2.
One version of this process is licensed
for various markets as HERO
TM
by such
frms as Aquatech, GE and U.S. Water,
while Veolia supplies their Opus
TM
tech-
nologies for this purpose. Keys to the pro-
cess are:
Micro- or ultrafltration to remove
suspended solids in the waste
stream.
Sodium bisulfte (NaHSO
3
) feed to
remove residual oxidizing biocides.
1304pe_52 52 4/4/13 9:19 AM
53
For info. http://powereng.hotims.com RS# 33 For info. http://powereng.hotims.com RS# 32
cases because of scale formation and
other chemistry issues within the wells
and the fact that the backpressure from
the wells often requires high-pressure
pumps for injection.
Yet another option, which was high-
lighted in Fig. 2, is direct injection of
cooling tower blowdown into the
ground without treatment. Again, this
process involves transfer of the water into
an injection well or wells, and any plant
personnel pondering such a strategy
must thoroughly evaluate this option and
present the case to their respective envi-
ronmental authorities.
Saving the best (or worst) for last is
true ZLD with thermal evaporation/
crystallization (E/C) of the remaining
waste stream. This technology utilizes
a heat source such as plant steam to re-
move most of the remaining moisture in
an evaporator, followed by conversion
of the remaining salts to a solid cake in
a crystallizer. Common evaporator types
Dan Sampson offered the following com-
ments in a recent issue of Industrial Water-
World: If you have any options at all, you
dont do zero liquid discharge. It really is
a completely separate chemical plant on
the back end of your power plant, and
you end up operating your power plant
trying to make the chemical plant work.
Its very diffcult. [1]
With this advice in mind, evaporation
ponds are a potential solution for plants
in arid locations with suffcient property.
However, regulatory personnel are close-
ly examining waste ponds of any type,
and it is virtually certain that any pond
will require an approved and properly-in-
stalled liner to prevent stored water from
leaching into the ground.
Another method that has been uti-
lized in some locations is deep-well in-
jection. Here, the wastewater is pumped
several thousand feet underground,
below any potable water aquifers. This
method has proven problematic in some
produce water of suffcient purity that
only fnal polishing is needed for puri-
fying the water for injection into a high-
pressure steam generator. Given that the
wastewater stream from a plant with a
cooling tower should be much greater
than the boiler makeup needs, plenty of
high-quality water will remain from the
wastewater treatment process. Any excess
could be utilized to improve the makeup
quality of other sources, such as the cool-
ing tower itself and evaporative coolers
for the combustion turbines.
Besides the potential for 90 percent
water recovery, the process is designed
to minimize the waste stream that must
then be disposed. In some cases, the
stream may be discharged to a sanitary
waste treatment facility or to a receiving
body of water, as the volume is slight. If
the plant is required to be a ZLD facil-
ity, treatment of the fnal waste stream
is where cost and complexity are great-
est. In fact, noted water treatment expert
1304pe_53 53 4/4/13 9:19 AM
www.power-eng.com
54
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continuously, but at a decreased produc-
tion capability over the planned design.
Thus, the system becomes a pinch point
for plant operation.
LESSONS LEARNED
As was mentioned earlier, the pro-
cess outlined in Fig. 2 is becoming more
popular for wastewater reduction at
power plants. However, the technology
is not without lessons learned, as some
of my colleagues and I have directly ex-
perienced. First, we have observed that
some standard cooling tower treatment
chemicals can cause fouling in the waste-
water treatment system. Most notable
is UF membrane fouling by suspended
solids dispersants. We are continuing to
investigate this issue, but strong infu-
ences on the fouling appear to include
the membrane style (inside-out fow vs.
outside-in) and the membrane manufac-
turer. We have also found that without
a clarifer upfront of
the process, coagulant
feed with multi-media
flter treatment ahead
of the UF may have
little effect on disper-
sant removal. Another
issue is the choice of
membrane backwash
water. Water high in
silica can react with
magnesium or calci-
um to form silicate de-
posits that also restrict
fow and are diffcult
to remove.
INTERNAL
PRODUCTION?
Last year in Power
Engineering, a col-
league and I wrote
about a technology
that can allow a plant
to potentially become
a net generator of wa-
ter. [2] The process
was originally designed for combustion
turbine inlet air cooling, and a fow dia-
gram is shown in Figure 3.
The technology utilizes straightfor-
ward ammonia refrigeration with com-
bustion turbine waste heat as the energy
source to cool the inlet air to the compres-
sor. However, by placing additional cool-
ing coils in the exhaust of a combined-
cycle unit, water from the fue gas can be
condensed and recovered. The key point
is that a signifcant quantity of water is
produced during combustion of natural
gas via the following reaction.
CH
4
+ 2O
2
CO
2
+2H
2
O
For even a reasonably sized combus-
tion turbine, the theoretical water re-
covery is perhaps one hundred to three
hundred gallons per minute. Thus, for
combustion turbines located in arid loca-
tions, substantial water recovery is pos-
sible due almost solely to the H
2
O pro-
duced in the combustion process.
CONCLUSION
This article outlines a number of the
current trends regarding water conser-
vation and recovery. These processes
continue to emerge where choices
must be made with technical and envi-
ronmental issues as main drivers.
Space did not permit a discussion
of wastewater treatment issues at
coal-fred plants with streams from
FGD systems that contain high
concentrations of chlorides, sulfates
and calcium as well as trace metals and
metalloids including boron, mercury
and selenium.
Some of the same but also other
technologies are required for treat-
ment of these streams.
References
1. J. Laughlin, Examining ZLD Options for
Electric Power Facilities; Industrial Wa-
terWorld, September/October 2012.
2. Buecker, B. and C. Mieckowski, Turbine
Inlet Air Cooling: Cutting Edge Technol-
ogy; Power Engineering, April 2012.
include falling-flm and forced-circula-
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reduce energy consumption is to ap-
ply a vacuum to the vapor discharge,
which lowers the boiling point. I have
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of these systems but have also seen ex-
amples where the system may operate
1304pe_54 54 4/4/13 9:19 AM
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INDEX
RS# COMPANY PG# SALES OFFICE RS# COMPANY PG#
1421 S. Sheridan Rd., Tulsa, OK 74112
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1304pe_C3 C3 4/4/13 9:04 AM
1304pe_C4 C4 4/4/13 8:59 AM

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