Fuel Tech, Inc. · NASDAQ:FTEK
Fuel Tech — IDEA Campus 2013
26 slides from Fuel Tech's conference presentation, 2013
Slide 1: UT Austin Efficiency Improvements & ULTRA System
Juan Ontiveros Executive Director IDEA Campus 2013 Utilities and Energy Management University of Texas - Austin Kevin Dougherty VP Business Development & Marketing Fuel Tech, Inc. UT Austin Efficiency Improvements & ULTRA™ System
Slide 2: Agenda
Agenda • University of Texas at Austin o Utilities & Energy Management Overview o Achievements in Energy Efficiency o 2008 CHP Upgrade, Equipment Description, Emissions Control • Reagent Decision for SCR o Urea versus Ammonia, Safety and Risk Considerations o On-site Urea Conversion Systems • ULTRA™
Slide 3: Investments
Investments •$33 Million – Cash Based – UEM Budget •$138 Million – Revenue Bonds Electricity Total Capacity Efficient •Increased - 85 MW to 137 MW Equipment Matched to Campus Loads Cooling Total Capacity •Increased From 30.5K tons to 54K tons •Includes 4 million gallon TES Steam Plant Capacity •Incr
Slide 4: Investments and Payback on Investments since 1996
Investments •$33 Million – Cash Based •$138 Million – Revenue Campus Bonds Growth 4.2 million GSF vs. 1996 • Plant Efficiency Improved 40% • Fuel Use Reduced to 1976 levels (9 million More GSF) • Water for Generation Decreased 25% • Sewer Costs Decreased by 51% • 99.9998 % Reliability for 40 years P
Slide 5: Gas Turbine #10 and Heat Recovery Steam Generator #10
GAS TURBINE #10 AND HEAT RECOVERY STEAM GENERATOR #10 32 MW GE LM2500 + DLE GT generator w/Heat Recovery Steam Generator (HRSG) & SCR with Cormetech CM-21 Catalyst
Slide 6: SCR System Reagent Options
SCR System Reagent Options Flammability • Anhydrous Ammonia Health Reactivity o Least Expensive (Coming in the Gate) Ammonia {NH3} o Extremely Hazardous Chemical, Highest Risk Protection o Requires RMP, Extensive Safety Training, Evacuation Plan • Aqueous Ammonia o 29% Concentration – Limited Availa
Slide 7: Urea vs. Ammonia – Other Considerations
Urea vs. Ammonia – Other Considerations • Safety o Safety can be Engineered into the Design, Reducing but Not Eliminating Risk • Natural Gas Pricing o Natural Gas is the Raw Material Used for Fertilizer Production o Downward Trend in NG Price May Result in Increased Domestic Fertilizer Production, M
Slide 8: Historical Bulk Urea and Ammonia Pricing
Historical Bulk Urea and Ammonia Pricing
Slide 9: ULTRA: On-site Urea Conversion
ULTRATM: On-site Urea Conversion Thermal Decomposition Process o Energy Required for Decomposition Typically Provided by Natural Gas or Oil-fired Burner, Electric Heater o Urea Flow Adjusted by NH3 Demand Signal Sent to the Metering Pumps o Fast Response, Good Turndown Image Courtesy of Fuel Tech, I
Slide 10: Urea Supply Considerations
Urea Supply Considerations • Urea Can Be Sourced in Solid Form o Prill or Granular Forms o Solid urea can be Solutionized On-site • Urea Can Be Sourced as High Purity Aqueous Solution • Economics favor solutionizing with larger systems • ULTRA process compatible with a wide range of urea sources o N
Slide 11: ULTRA and SCR Process Schematic
ULTRA™ and SCR Process Schematic CEMS Signal SCR DCS Control NOx, CO from Analyzer Urea Feed Rate Signal Urea Storage Metering Tank Pumps 100% Spare Urea Injection Natural Gas Burner Decomposition Ambient Chamber Air 100% Spare NH3 & HNCO to Ammonia Injection Grid
Slide 12: ULTRA System Schematic
ULTRA™ System Schematic Natural Gas Natural Gas Supply Fuel Module Ammonia Injection Grid Dilution Air Blowers Urea Storage Tank 8,000 GAL Metering and Distribution Module SCR 3200 Urea Aspirating Air Atomizing Supply Air Supply Urea Injector Flush Water Atomizing Air Instrument Air Supply Decomposi
Slide 13: Thermal Decomposition of Urea
Thermal Decomposition of Urea Heat Source in the Carrier Medium: Form of Burner, Electric Ambient Air, Clean Heat, or Hot Flue Gas Flue Gas Process Delivers Reagent to Static Mixer Injection of Aqueous and NH3 Injection Grid (AIG) at Required Urea Urea in Temperature Pressure and Temperature Based o
Slide 14: ULTRA Process Modeling
ULTRA™ Process Modeling • Computational Fluid Dynamics (CFD) Modeling of Decomposition Chamber • Modeling of Temperature, Residence Time, and Droplet Dispersion • Evaluation of Urea Injection Strategies
Slide 15: ULTRA System Configuration
ULTRA™ System Configuration • System Designed for 40% or 32% Urea (40% Initial Operation) • 24.7 lb-NH3/hr maximum and 2.47 lb-NH3/hr minimum • 8,000 Gallon FRP Concentrated Urea Storage Tank • Two (2) 100% Dilution Air Blowers • One (1) Metering and Distribution Module • One (1) Natural Gas Burner
Slide 16: ULTRA System Illustration
ULTRA™ System Illustration
Slide 17: Urea Conversion System Selection
Urea Conversion System Selection • Constrained Site • 50,000 Students in the Region • Campus Safety is Paramount
Slide 18: Power Plant
Power Plant 2012 CAMPUS SIZE 18,000,000 Square Feet IN 150 BUILDINGS NATURAL GAS PURCHASED 3,996,000 MMBTU 3,996,762 ELECTRICITY DISTRIBUTED 345,000,000 345,000,000 KWH CO 2 e RELEASED 220,000 220,000 TONS
Slide 19: LITT T7
a Za LITT T7
Slide 20: Ammonia Risks
Ammonia Risks Anhydrous Ammonia Aqueous Ammonia Not Much Better
Slide 21: Urea Conversion System Selection
Urea Conversion System Selection • Safest and Most Effective Alternative to the Use of Ammonia in our Campus • Met Overall Performance and Turndown Requirements • Satisfied Need to Work within a Limited Footprint • Accepted by SCR and Catalyst Providers • Proven Track Record in Similar Applications
Slide 22: Fuel Tech System Performance
PPM PPM Fuel Tech System Performance 35 35 9.5 9.5 30 30 7.5 7.5 25 25 Steady NOx at 5 PPM 5.5 5.5 20 20 15 15 3.5 3.5 10 10 1.5 1.5 55 -0.5 -0.5 00 Urea FlowUrea (GPH) Flow Urea Outlet (GPH) Flow NH3 (CEMS-ppm) (GPH) MW Oulet Nox Outlet(CEMS-ppmc) TurbNH3 Flow (klb/hr) MW Gas(CEMS-ppm) Linear (Oule
Slide 23: Deposit Problem
t Problem Depos ii yi
Slide 24: Operational/Equipment Issues and Lessons Learned
Operational/Equipment Issues and Lessons Learned • Deposits created as Ammonium bisulfate o Formed at about 400°F o React with tube material to form iron sulfate – corrosion • Confusion on where the sulfur was coming from o Analyzed Natural Gas – nothing o Analyzed Urea – nothing • Most likely the s
Slide 25: Air Intake Narrowed the NH3 Control Range
Air Intake Narrowed the NH3 Control Range Similar Problem on Boiler 7
Slide 26: Summary
Summary • ULTRA System Operating Since 2008 • Was the Right Choice for our Application • No Issues with Urea Availability or Delivery • Good Support for Start-up Issues, Minor Equipment Issues and Ongoing • No Emissions Issues