Fuel Tech, Inc. · NASDAQ:FTEK
Fuel Tech — 2017 International Biomass Conference
31 slides from Fuel Tech's conference presentation, Apr 10, 2017
Slide 1: Minimizing Slag, Fouling, and Corrosion in Biomass-Fired Units
2017 International Biomass Conference April 10-12, 2017 Minimizing Slag, Fouling, and Corrosion in Biomass-Fired Units Dr. Ian Saratovsky, Director Chemical Products
Slide 2: Agenda
Agenda • Deposit formation and impacts • Fuel Tech’s TIFI® technology platform • Technology selection for biomass-fired units • Mechanism of operation • Impacts of TIFI on corrosion • TIFI program detail • Questions and comments 2
Slide 3: Slag and Fouling Mechanism
Slag and Fouling Mechanism • Slag deposition o Condensation of molten, viscous inorganic species on colder surfaces (e.g. heat transfer tubes) o Typically on water walls, superheater tubes, generating bank tubes • Fouling o Deposition of gaseous species onto colder surfaces (e.g. heat transfer tubes
Slide 4: Impacts of Slag/Fouling on Unit Operations
Impacts of Slag/Fouling on Unit Operations • Restricted gas flow path o Build up between tubes results in pressure differential o Induced draft (ID) fan load increases to maintain prescribed draft • Reduced heat transfer efficiency o Downtime for cleaning/explosive de-slagging o Diminished heat abso
Slide 5: TIFI Targeted In-Furnace Injection
TIFI® Targeted In-Furnace Injection™ TIFI nozzle injecting chemical additive(s) 5
Slide 6: Slag/Fouling Control with TIFI
Slag/Fouling Control with TIFI • Fuel flexibility o Slagging, fouling, corrosion control with all types of biomass fuels o Ability to fire opportunity fuels with lower ash fusion temperatures o Co-firing applications, i.e. woody biomass and agricultural waste • Targeted injection towards problem are
Slide 7: Key Technologies to Control Slagging & Fouling
Key Technologies to Control Slagging & Fouling Untreated Slag • Deposit Analysis • Computational fluid dynamics (CFD) • Injection technology TIFI Treated Slag • Chemical technology • Combustion expertise 7
Slide 8: Impact on Deposit Physical Properties
Impact on Deposit Physical Properties Scanning Electron Microscope (SEM) at 5.5x magnification Deposit without TIFI® Deposit treated with TIFI® Numerous small pores with thick walls Larger pores with thin walls 8
Slide 9: Hard Slag Formation Controlled
Hard Slag Formation Controlled Furnace side After TIFI® treatment • More pores • Less dense • Softer • Easier to crumble/remove • Example of friable slag created via TIFI use Before TIFI® treatment • Tenacious • Less pores and smaller • Hard • More dense Wall side 9
Slide 10: Enhanced Efficacy Through Targeted Application
Enhanced Efficacy Through Targeted Application 10
Slide 11: Opportunity to Switch Fuels/Co-Fire
Opportunity to Switch Fuels/Co-Fire • Design: burn coal with Tfusion= 1150° (Green) • Goal: burn coal with Tfusion = 1370°C (Blue) Low Cost Fuel Tmelt = 1150 oC • Less costly fuel (Blue) • Ability to co-fire different fuels • Biomass Design Fuel • Oil Tmelt = 1370 oC • Coal • RDF • TDF 11
Slide 12: Targeting Chemistry to Problem Areas
Targeting Chemistry to Problem Areas • Fuel analyses/combustion/laboratory data used to predict problem areas o Visual inspections are used to validate/tune model • TIFI program is designed to specifically target problem areas 12
Slide 13: Chemical Technology Selection
Chemical Technology Selection 13
Slide 14: Additive Selection Summary
Additive Selection Summary • Biomass ash (and deposit) chemistry is highly variable o Deposit formation driven by: SiO2:Al2O3 ratio Alkali metals (K+, Na+) Iron Phosphates Low-melting silicates • Additives must be selected separately for each fuel o Empirical testing is critical! • Predict
Slide 15: Scientific Approach to Additive Selection
Scientific Approach to Additive Selection • Fuel and deposit samples analyzed o Chemistry, physical properties, and ash fusion temperatures • Several chemical additives available o Which one is most effective? • Laboratory screening studies conducted o Determination of cost-effective additives 4,500
Slide 16: Biomass SH Deposit Compression Strengths
Biomass SH Deposit Compression Strengths Compression Test Results 9000 8000 7000 Compression Max Load (lbs) 6000 5000 4000 3000 2000 1000 0 Baseline MG Hi MG Med MG Lo ATH Hi ATH Med ATH Lo Kaolin Hi Kaolin Med Kaolin Lo Fly ash Hi Fly ash Fly ash Lo MG/ATH MG/ATH MG/ATH Baseline A(Hi) A(Med) A(Lo)
Slide 17: Biomass Economizer Deposit Strengths
Biomass Economizer Deposit Strengths 4500 Compression Strength Applied to Breakage (lbs) 4000 3500 3000 2500 2000 1500 1000 500 0 Baseline A(Hi) Baseline TIFI A(Med) MG TIFI A(Lo) MG TIFI MG ATH B(Med) B(Hi)Hi ATH B(Lo) Med ATH C(Hi) Hi C(Med) Low Kaolin Kaolin C(Lo) Kaolin Hi Med Low Med Low 17
Slide 18: Controlling Corrosion
Controlling Corrosion • Chloride-induced corrosion is directly related to the presence of slag/fouling deposits • Deposit-free heat transfer surfaces result in significantly lower metal loss rates due to corrosion • TIFI reduces corrosion rates by keeping surfaces free of deposits
Slide 19: Minimizing Corrosion Through Deposit Control
Minimizing Corrosion Through Deposit Control 25 Location: reheater Baseline 20 Metal,Loss,per,Year,(mpy) 15 10 TIFI MG 5 corrosion Erosion component 0 Baseline,(no,treatment) Weigh.,347,day,Avg,errosion,+,other,loss 19
Slide 20: Case Studies
Case Studies
Slide 21: TIFI History in Slag/Fouling/Corrosion Control
TIFI History in Slag/Fouling/Corrosion Control • 20+ years of continuous treatment • 110+ boilers successfully treated o Utility boilers : 150 MW to 1300 MW o Industrial boilers : 10 MW to 100 MW • Demonstration of ROI o Ability to fire opportunity fuel/fuel blends o Increase net heat rate (NHI) o I
Slide 22: Comparison of Slag Deposits: TIFI vs. Baseline
Comparison of Slag Deposits: TIFI vs. Baseline Baseline (no treatment) Treated with TIFI 22
Slide 23: Westar Jeffrey Energy Center, Unit 2 (800 MW)
Westar Jeffrey Energy Center, Unit 2 (800 MW) • High calcium and sodium coal • Slagging/fouling result in de-rates and frequent outages for cleaning o FEGT climbed to 2500 oF (1370 oC) o 113 GW of generation lost in 2014 • TIFI® program installed in late 2014 o Increased interval between cleanings f
Slide 24: Impact of TIFI on Cleanliness
Impact of TIFI on Cleanliness Green shading when TIFI is in service Time between cleaning outages extended while TIFI is in service 24
Slide 25: Impacts of TIFI on Sootblowing (800 MW Unit)
Impacts of TIFI on Sootblowing (800 MW Unit) Unit 2 ‐ Treated Unit 3 ‐ Untreated 25
Slide 26: Black Liquor Firing
Black Liquor Firing • Black liquor recovery boiler o High alkali content Typical: ~20% sodium, ~2% potassium o High chloride content Typical: 0.3%-1.5% • Goal (1995) o Increase firing rate from 1100 metric tons/day to 3200 metric tons/day o Increase interval between water washes from ~ 50 - 90 d
Slide 27: Impact of TIFI on Cleaning Interval (1996)
Impact of TIFI on Cleaning Interval (1996) • Increased cleaning interval from 55 days to 96 days 27
Slide 28: Impact of TIFI on Cleaning Interval (2014-2016)
Impact of TIFI on Cleaning Interval (2014-2016) Mill maintenance Mill startup shutdown Water wash waterwash 2014 ‐ 2015 2015 ‐ 2016 • 11 month run completed with 4.07 MM lbs/day of BL dry solids firing 28
Slide 29: Annual Downtime Maintenance Hours: TIFI Bio vs. Competition
Biomass-Fired Process Furnace: TIFI BioTM vs. Competition 350 Brand X 300 Annual Downtime Maintenance Hours 250 200 TIFI BioTM 150 100 50 0 2015 2016 1 2 • Increased asset utilization rates • Avoided construction of a new furnace unit (> $10MM) 29
Slide 30: Summary
Summary • Targeted In-Furnace Injection (TIFI) o Targeted chemical injection is critical o Works in conjunction with sootblowers, impulse cleaners, sonic horns, etc. o Targets slag/fouling/corrosion in furnace and convective section • Combustion optimization and slag/fouling control can: o Increase
Slide 31: Questions?
Questions? Dr. Ian Saratovsky Director Chemical Technologies Isaratovsky@ftek.com