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19 April 2012

PRE AND POST COMBUSTION AQC EMISSIONS REDUCTION TECHNOLOGY OVERVIEW


QUALITY CONTROL SECTION PRATIK MEHTA AIR B&V ENERGY

AGENDA
About Black & Veatch NOx Control Methods SO2 Control Methods Particulate Control Methods CO & VOC Control Methods HAPs Control Methods AQC Implementation Challenges Questions & Open Discussions
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ABOUT BLACK & VEATCH

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POWER-GEN India

19 April 2012

BLACK & VEATCH CORPORATION IS A LEADING GLOBAL ENGINEERING, CONSULTING AND CONSTRUCTION COMPANY
Founded in 1915 Global workforce of more than 9,000 More than 100 offices worldwide Projects in more than 100 countries on 6 continents $2.6 billion in annual revenues in 2011 Ranked on Forbes Americas Largest Private Companies listing One of the largest majority employee-owned company in the U.S. Reputation of integrity, competence and highest safest standards

Ranked 1st in Power by Engineering News Record (ENR)

POWER-GEN India

19 April 2012

BLACK & VEATCH CONSULTING PVT LTD (PUNE)


Business in India from 1977; office established in 2004 Business Areas Energy and Telecom Workforce More than 150 professionals Energy Departments Engineering (Mechanical, Electrical & Controls, Civil & Structural), Project Control, Proposals, Procurement, Quality, Human Resources, and Administrative Office with project execution capabilities Equipped with commercial and B&V proprietary engineering tools

BVCPL Global Talent and knowhow brought locally

POWER-GEN India

19 April 2012

CAPABILITIES BY ENERGY SCOPE

ENGINEERING SERVICES
Techno Economic Feasibility Reports Detail Project Reports Owners Engineering Services Lenders Engineering Services Independent Engineer Services Detail Engineering Services

PROJECT SERVICES
Project Management Procurement Construction Management Startup Services Operator Training Outage Management

EXPANDED SCOPE
P E E E P P C CM

POWER-GEN India

19 April 2012

PROJECT APPROACH
Phase I
Project Development

Conceptual Engineering Detailed Cost Estimate Develop Design and Instruction Manuals Procurement Execution Plan Permitting Detailed, Multi-Discipline Engineering for Balance of Plant Interface with Existing Plant Systems Procurement Level 2/3 Schedule Development Project Controls Construction Management Quality Assurance Management Project Controls Startup and Commissioning Performance Testing
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Phase II
Detail Design Engineering

Phase III
Construction, Startup, and Commissioning

NOx CONTROL METHODS

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POWER-GEN India

19 April 2012

LOW NOx BURNERS AND OVER-FIRE AIR

Source: Babcock & Wilcox

Source: Siemens

Delayed combustion and air stagging

POWER-GEN India

19 April 2012

SELECTIVE CATALYTIC REDUCTION (SCR)


Gas Flow Distribution Devices Temperature Measurement Grid Vaporized Ammonia Catalyst

Sonic Horns Space For Future Catalyst and Sonic Horn Addition

Tuning / Monitoring Grid Flue Gas From Economizer Bypass Damper System (optional) Flue Gas to Air Heater 10

Most widely used post-combustion technology in the world

POWER-GEN India

19 April 2012

SELECTIVE NON CATALYTIC REDUCTION (SNCR)


Injection Level 1 Ammonia or Urea Storage Tank Injection Level 2

Injection Level 3

Burners

Steam Generator Air Heater Flue Gas Combustion Air

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POWER-GEN India

19 April 2012

IN-DUCT HYBRID SCR

Source: Clean Environmental Protection Engineering

Optimized ammonia usage

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POWER-GEN India

19 April 2012

NOx CONTROL METHODS COMPARISON


NOx Control Methods Controlled NOx emissions, mg/Nm3 Capital cost O & M cost Auxiliary power Pressure drop BOP impacts Fly ash sales impact Safety and hazard risks Additional pollutant or byproduct formation Additional AQC equipment required LNB 310 - 350 Low Low Low Low Reduced boiler efficiency None None High CO emissions None OFA 280 - 3001 Low Low Low Low Reduced boiler efficiency None None High LOI SCR 60 - 752 Highest Highest Highest Highest Air heater fouling Yes Yes Ammonium bisulfate Particulate control equipment upstream SNCR 210 - 2502 Medium Medium Medium Medium Air heater fouling Yes Yes Ammonium bisulfate None In-Duct Hybrid SCR 135 - 1602 High High High High Air heater fouling Yes Yes Ammonium bisulfate Particulate control equipment upstream 13

None

Notes: 1.When used in conjunction with LNB. 2.When used in conjunction with LNB and OFA.

POWER-GEN India

19 April 2012

Vaporized Ammonia Flue Gas

B&V NOx CONTROL METHODS EXPERIENCE


NOx Removal Experience from early 1980s LNB / OFA

Catalyst

25 + Engineering 7,900 MW +

SCR/SNCR
25 + Engineering 18,300 MW +

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SO2 CONTROL METHODS

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POWER-GEN India

19 April 2012

DUCT SORBENT INJECTION

Source: Solvay

Alkaline reagents - sodium or lime based sorbents

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POWER-GEN India

19 April 2012

WET FLUE GAS DESULFURIZATION

Most widely used technology in the world

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POWER-GEN India

19 April 2012

SEMI- DRY FLUE GAS DESULFURIZATION


Atomizers Stack Fabric Filter

Semi Dry FGD Reactor

Flue Gas Induced Draft Fan

Fly ash for Disposal Or Recycle

Integral particulate control equipment

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POWER-GEN India

19 April 2012

DRY FLUE GAS DESULFURIZATION

Second generation dry scrubber systems

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POWER-GEN India

19 April 2012

SEAWATER FLUE GAS DESULFURIZATION

Natural alkalinity of sea water

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POWER-GEN India

19 April 2012

SO2 CONTROL METHODS COMPARISON


SO2 Control Methods Controlled SO2 emissions, mg/Nm3 Capital cost Reagent cost O & M cost Auxiliary power Pressure drop SO3 removal HCl removal HF removal Particulate removal Oxidized mercury removal Material of construction Furnace or Duct Sorbent Injection 120 - 160 Low High Low Low Low High Low Low High Low Carbon Steel Wet FGD 50 - 75 High Low High High High Medium High High Medium High High corrosion resistant alloy or non-metallic liner or FRP Yes - may require waste water treatment plant Saleable Gas to Gas Reheater Semi-Dry FGD 80 - 100 High High Medium Medium Medium High High High High High Carbon Steel Dry FGD 80 - 100 High High Medium Medium High High High High High High Carbon Steel Seawater FGD 100 - 120 Medium None Low Medium Medium Medium High High Medium High High corrosion resistant alloy or non-metallic liner or FRP Yes - discharge to sea None Gas to Gas Reheater

Liquid waste Byproduct sales impact Additional AQC equipment required

None Not saleable Particulate control equipment downstream

None Not saleable Particulate control equipment downstream

None Not saleable Particulate control equipment downstream

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POWER-GEN India

19 April 2012

B&V FGD EXPERIENCE


SO2 Removal Experience from early 1960s SO2 Removal Experience from 4 MW to 900 MW FGD
90+ Engineering 42,600 MW+

OEM experience Third party scrubber experience


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PARTICULATE CONTROL METHODS

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POWER-GEN India

19 April 2012

DRY ELECTROSTATIC PRECIPITATOR (DESP)

Source: Babcock & Wilcox

Most widely used technology in the world

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POWER-GEN India

19 April 2012

FABRIC FILTER (FF)

Outlet poppet damper Pulse Air Header Filter Bag with internal cage Pulse air pipe Outlet manifold Tube sheet Inlet manifold Inlet louver damper

Source: Babcock & Wilcox

Second generation particulate control equipment

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POWER-GEN India

19 April 2012

WET ELECTROSTATIC PRECIPITATOR (WESP)

Source: Babcock & Wilcox

Fine particulate control equipment

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POWER-GEN India

19 April 2012

PARTICULATE CONTROL METHODS COMPARISON


Particulate Control Methods Controlled particulate emissions, mg/Nm3 Capital cost O & M cost Auxiliary power Pressure drop SO3 removal Fine particulate removal Mercury removal Fuel and operating flexibility Temperature limitations Reagent injection for multipollutant capabilities Material of construction Liquid waste Additional AQC equipment required DESP 50 - 75 Low Low Medium Low Low Low Low Low None Limited Carbon Steel None None FF 15 - 20 High High Medium High Low Medium Medium High Yes Good Carbon Steel None None WESP Co-benefit Low Low High Low High High High Medium None None High corrosion resistant alloy or non-metallic liner or FRP Yes Wet FGD system upstream 27

POWER-GEN India

19 April 2012

B&V ESP AND PJFF EXPERIENCE


Particulate Removal Experience from 4 MW to 825 MW ESP
100+ Engineering 24,500 MW+

FF
50+ Engineering 13,000 MW+

ESP Dry & Wet FF PJFF and RGFF


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CO & VOC CONTROL METHODS

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POWER-GEN India

19 April 2012

OXIDATION CATALYST

CO2 + H2O From CT CO VOC

Oxidation Catalyst

Ammonia Injection Grid

SCR Catalyst

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HAPS CONTROL METHODS

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POWER-GEN India

19 April 2012

POWDERED ACTIVATED CARBON (PAC) INJECTION

Source: Nol-Tec Systems 32

AQC IMPLEMENTATION CHALLENGES

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POWER-GEN India

19 April 2012

AQC IMPLEMENTATION CHALLENGES


Retrofit Space constraints Programming methodology Initial study to execution Compliance strategy Future emission limits Customized solutions Not one technology fits all Outage planning Strong partners and team

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POWER-GEN India

19 April 2012

ELEMENTS OF EXECUTION SUCCESS


Mitigating and managing risk Controlling cost and schedule through project planning and management of change Keeping the labor force engaged and safe Achieving performance and quality goals

Our team and our processes are focused on achieving success for the Owner

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POWER-GEN India

19 April 2012

PROJECT PLANNING AND CONTROL


Preliminary Design Planning Cost Estimating Manpower Estimate Schedule Development Outage Planning Construction Planning Risk Identification Project Execution Project Monitoring and Forecasting Adjustments and Mitigation (as needed) Successful Project Completion

The payoff of planning


B&V can accurately assess the performance of the project and make EARLY corrections, when needed

Plan the work, Work the plan

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QUESTIONS & OPEN DISCUSSIONS


CONTACT US: BOOTH 1139 - HALL 11

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www.bv.com