Fuel Tech, Inc. · NASDAQ:FTEK
Fuel Tech — XV ICESP Conference 2018
57 slides from Fuel Tech's conference presentation, 2018
Slide 1: Dual Flue Gas Conditioning: Processes, Technology and Experience
Dual Flue Gas Conditioning Processes, Technology and Experience Henry V. Krigmont, Ph.D. and James J. Ferrigan
Slide 2: SO3 Flue Gas Conditioning (SO3 FGC)
SO3 Flue gas Conditioning (SO3 FGC)
Slide 3: SO3 Flue Gas Conditioning
SO3 FLUE GAS CONDITIONING When coal is subjected to pulverized fuel combustion, the sulphur it contains is converted to the oxides of sulphur in the gas phase 3
Slide 4: SO3 Flue Gas Conditioning
SO3 FLUE GAS CONDITIONING • SO3 and H2O combine in the flue gas to form H2SO4 • H2SO4 and H2O are adsorbed on the surface of the fly ash particles at flue gas temperatures below 204 °C (400 °F) 4
Slide 5: SO3 Flue Gas Conditioning
SO3 FLUE GAS CONDITIONING • In general, SO3 is formed by a catalytic conversion of gaseous sulfur dioxide (SO2). • The SO2 usually comes from an "external" source (feedstock) by either evaporating liquid sulfur dioxide or by burning molten or solid sulfur. 5
Slide 6: SO3 Flue Gas Conditioning
ALENTEC ALLed Environmental Technologies Tne. SO, FLUE GAS CONDITIONING ‘Option-Dry Sulfur Steam Jacketed Molten Detwery vy Pump ‘Sulfur Molten Storage —— Dry Sur Unloading Hobe RK — steam Supply ‘SO, Production Enclosure ‘Steam Pipe > ‘Steam Jacketed > Metering Pumps: Sie Note acta Pune Erne Steam
Slide 7: Indigenous Flue Gas Conditioning (iCON) Concept & Operation
Indigenous Flue Gas Conditioning (iCON™) Concept & Operation
Slide 8: From Today to Tomorrow…
FROM TODAY TO TOMORROW… • Conventional flue gas conditioning systems have two major drawbacks: o they require an external continuous supply of a feedstock and o in the process of operation these systems slightly increase SO2 emissions • Another approach to create SO3 is to utilize a "native" SO2 for
Slide 9: iCON: Indigenous Flue Gas Conditioning
ICON ™: INDIGENOUS FLUE GAS CONDITIONING SO3 Electrostatic Flue Gases Precipitator SO2 SO2 to SO3 SO3 Catalytic SO2 Converter Heat 9
Slide 10: iCON: Indigenous Flue Gas Conditioning
ICON ™: INDIGENOUS FLUE GAS CONDITIONING 10
Slide 11: iCON: Indigenous Flue Gas Conditioning
ICON ™: INDIGENOUS FLUE GAS CONDITIONING • There is NO NEED FOR AN “EXTERNAL” FEEDSTOCK (dry/pelletized or molten sulfur, SO2, H2SO4, etc.) • VERY LOW COST of operation and maintenance • iCON™ is offering virtually INSTANTANEOUS ON-DEMAND AVAILABILITY 11
Slide 12: Ammonia Flue Gas Conditioning
Ammonia Flue Gas Conditioning
Slide 13: Ammonia Flue Gas Conditioning
AMMONIA FLUE GAS CONDITIONING o First reports of the intermittently successful use of ammonia as a conditioning agent were reported in Australia by Watson and Blecher in 1966. o The results of their study showed effectiveness of using the ammonia as a conditioning agent. o There, the SO3 flue gas co
Slide 14: Ammonia Flue Gas Conditioning
AMMONIA FLUE GAS CONDITIONING • Fundamental explanations of the effects of ammonia conditioning have assumed that the chemical compounds formed are: o ammonium bisulfate NH4HSO4 or, o if the stoichiometric ratio is appropriate, the normal sulfate (NH4)2SO4 14
Slide 15: Ammonia Flue Gas Conditioning
AMMONIA FLUE GAS CONDITIONING • The chemical reactions postulated by Rendle and Wildson suggested that ammonia will react with any sulfur trioxide and moisture present to produce ammonium bisulfate 𝑵𝑵𝑵𝑵𝟑𝟑 (𝒈𝒈𝒈𝒈𝒈𝒈) + 𝑺𝑺𝑺𝑺𝟑𝟑(𝒈𝒈𝒈𝒈𝒈𝒈) + 𝑯𝑯𝟐𝟐 𝑶𝑶(𝒈𝒈𝒈𝒈𝒈𝒈) →…
Slide 16: Ammonia Flue Gas Conditioning
AMMONIA FLUE GAS CONDITIONING • Melting point of ammonium bisulfate (𝑵𝑵𝑵𝑵𝟒𝟒 𝑯𝑯𝑯𝑯𝑯𝑯𝟒𝟒 ) is 146.9°C (297°F) • Therefore, lacking excess ammonia or as cooling occurs the liquid ammonium bisulfate will freeze at temperatures below 147°C (297ºF) into a sticky solid • It is this adherent…
Slide 17: Ammonia Flue Gas Conditioning
AMMONIA FLUE GAS CONDITIONING • In fact, ammonia works as a scavenger, hunting down each free molecule of the SO3 producing several ammonium salts 17
Slide 18: Ammonia Flue Gas Conditioning
AMMONIA FLUE GAS CONDITIONING NH4HSO4 SO3 (NH4)2SO4 H2SO4 SO3 SO3 H2O H2O NH3 SO3 H2SO4 H2O 18
Slide 19: Ammonia Flue Gas Conditioning
AMMONIA FLUE GAS CONDITIONING • Because the presence of H2SO4 reduces the amount of SO3 available in the flue gas to react with NH3, formation of the sulfuric acid o 𝑺𝑺𝑺𝑺𝟑𝟑 + 𝑯𝑯𝟐𝟐 𝑶𝑶 ↔ 𝑯𝑯𝟐𝟐 𝑺𝑺𝑺𝑺𝟒𝟒 • Was noted as, perhaps, the most important principle chemical reaction for the…
Slide 20: Ammonia Flue Gas Conditioning
AMMONIA FLUE GAS CONDITIONING • Anhydrous NH3 feedstock requires least energy input • Anhydrous system utilizes uninsulated carbon steel piping for transport to the injection probes for lowest cost installation • 2,000 gallon tank is under the threshold for Risk Management Plans and intensive safety
Slide 21: ULTRA Urea to Ammonia Process
ULTRA™ UREA TO AMMONIA PROCESS 21
Slide 22: Ammonia FGC & Fly Ash Resistivity
Ammonia FGC & Fly Ash Resistivity
Slide 23: Ammonia FGC & Fly Ash Resistivity
AMMONIA FGC & FLY ASH RESISTIVITY • The reaction of ammonia with sulfur trioxide to produce ammonium sulfate or ammonium bisulfate appears to have been a key event in the occurrence of either type of conditioning process • Dr. Dismukes and his team investigated concentrations of ammonia, sulfur oxid
Slide 24: Ammonia FGC & Fly Ash Resistivity
AMMONIA FGC & FLY ASH RESISTIVITY • Subsequently, direct measurements of resistivity were made with a point-to-plane probe in situ as described by Dr. White • Comparative values of the data obtained with ammonia injected at concentrations of 7 to 20 ppm by volume show no significant change in resist
Slide 25: Ammonia FGC & Fly Ash Resistivity
AMMONIA FGC & FLY ASH RESISTIVITY • Thus, it had been demonstrated that fly ash shows no significant change in resistivity as a result of ammonia conditioning • However, ammonia does improve the efficiency of fly ash precipitation through two mechanisms: o the first: consisting of a space-charge eff
Slide 26: Dual Flue Gas Conditioning (DFGC)
Dual Flue Gas Conditioning (DFGC)
Slide 27: Dual Flue Gas Conditioning
DUAL FLUE GAS CONDITIONING A DFGC system, by providing the independent and simultaneous injection of SO3 and NH3 in strictly controlled stoichiometric ratios, allows for a further collection efficiency improvement when compared to SO3 injection on its own NH3 SO3 27
Slide 28: Dual Flue Gas Conditioning
DUAL FLUE GAS CONDITIONING The injection of ammonia promotes improved utilization (uptake) of the SO3, forming ammonium bisulfate resulting in more effective resistivity control 28
Slide 29: Dual Flue Gas Conditioning
DUAL FLUE GAS CONDITIONING • Depending on the NH3 to SO3 stoichiometric rates, ammonia can produce low melting point substances • DFGC by producing ammonium bisulfate increases the cohesiveness of fly ash particles and thus reduces the reentrainment of ash deposited on the collection electrodes • Co
Slide 30: Dual Flue Gas Conditioning
DUAL FLUE GAS CONDITIONING • In addition, injection of ammonia (NH3) into the flue gases in the presence of SO3 results in the formation of submicron particles of ammonium sulfates • DFGC improves the ESP performance due to an additional space charge, which alters the electrical characteristics of t
Slide 31: Case Studies
ALENTEIEC Case Studies FUEL TECH
Slide 32: Shenhua Zhungeer Power Station
Shenhua Zhungeer Power Station
Slide 33: Shenhua Zhungeer Power Station
SHENHUA ZHUNGEER POWER STATION • Zhungeer Power Station is a 1,570-megawatt (MW) coal-fired power plant located at the suburbs of Jungar, Ordos (E'erduosi) Prefecture, Inner Mongolia Autonomous Region • The local coal is being delivered from the Zungeer mine • It is thought that Zhungeer coal ash is
Slide 34: Shenhua Zhungeer Power Station
SHENHUA ZHUNGEER POWER STATION • There is one (1) ESP with two (2) chambers, two (2) cells per each unit • Each cell houses forty-seven (47) gas passages on 305 mm (12 inches nominal) centers • Each ESP has five (5) mechanical fields in the direction of the gas flow: o first three fields are 3.00 m
Slide 35: Shenhua Zhungeer Power Station
SHENHUA ZHUNGEER POWER STATION 35
Slide 36: Shenhua Zhungeer Power Station
SHENHUA ZHUNGEER POWER STATION 36
Slide 37: Shenhua Zhungeer Power Station
SHENHUA ZHUNGEER POWER STATION • The final emissions were tested with SO3 FGC only and the results were as follows: o Unit 1 achieved 18 mg/Nm3 (0.00786 gr./dscf) at ESP outlet o Unit 2 achieved 17 mg/Nm3 (0.00743 gr./dscf) at ESP outlet 37
Slide 38: NRG Energy – Morgantown Power Station
NRG Energy – Morgantown Power Station
Slide 39: NRG Energy – Morgantown Power Station
NRG ENERGY – MORGANTOWN POWER STATION • Morgantown Generating Plant is located in Newburg, Washington, D.C. area in Charles County, Maryland on the Potomac River • The boilers, manufactured by Combustion Engineering (CE), are rated at 640 MW • Each boiler is a tangentially coal fired supercritical u
Slide 40: NRG Energy – Morgantown Power Station
NRG ENERGY – MORGANTOWN POWER STATION • The project team identified a comprehensive two- phase approach to reduce the stack opacity: o (a) Phase I included the Numerical Electrostatic Precipitator (NEP) model, and o (b) Phase II consisted of ESP upgrade (split 1st fld.) and DFGC. • The latter result
Slide 41: NRG Energy – Morgantown Power Station
NRG ENERGY – MORGANTOWN POWER STATION 41
Slide 42: NRG Energy – Morgantown Power Station
NRG ENERGY – MORGANTOWN POWER STATION 42
Slide 43: Minnesota Power - Taconite Harbor Energy Center
Minnesota Power - Taconite Harbor Energy Center
Slide 44: Minnesota Power Taconite Harbor Energy Center
MINNESOTA POWER TACONITE HARBOR ENERGY CENTER • Taconite Harbor Energy Center is a coal-fired power station near Schroeder, Minnesota • The facility is a coal-fired steam electric utility generating plant located on the north shore of Lake Superior • The plant burns western bituminous and sub- bitum
Slide 45: Minnesota Power Taconite Harbor Energy Center
MINNESOTA POWER TACONITE HARBOR ENERGY CENTER • Due to the installation of a Lime Based Sorbent and other agents used to lower SOx and NOx emissions (Mobotec Process), particulate load had increased • The exiting hot-side ESP was not able to handle the speed of gas flow to effectively collect the ex
Slide 46: Minnesota Power Taconite Harbor Energy Center
MINNESOTA POWER TACONITE HARBOR ENERGY CENTER • The chosen cold-side ESP design had: o one (1) ESP with two (2) chambers, single cell per each unit o each cell houses eighteen (18) gas passages on 305 mm (12 inches nominal) centers o ESP has six (6) electrical and three (3) mechanical fields in the
Slide 47: Minnesota Power Taconite Harbor Energy Center
MINNESOTA POWER TACONITE HARBOR ENERGY CENTER • The successfully performed hot-to-cold retrofit augmented by the use of DFGC, enabled the plant to outperform the 0.03 lbs./MBtu (22.61 mg/Nm3, wet) outlet emissions • The equipment upgrade also resulted in an improved reliability and performance 47
Slide 48: Minnesota Power Taconite Harbor Energy Center
MINNESOTA POWER TACONITE HARBOR ENERGY CENTER 48
Slide 49: Minnesota Power Taconite Harbor Energy Center
MINNESOTA POWER TACONITE HARBOR ENERGY CENTER 49
Slide 50: Current & Future DFGC Applications
Current & FUTURE DFGC APPLICATIONS
Slide 51: Current & Future DFGC Applications
CURRENT & FUTURE DFGC APPLICATIONS • Indian power plant • Super critical 660MW unit • Eight (8) fields ESP • Moderate SCA of 91.23 m2/m3/s 51
Slide 52: Current & Future DFGC Applications
CURRENT & FUTURE DFGC APPLICATIONS FGC Option === > w/o SO3 w/SO3 w/Dual FGC ITEM English Metric English Metric English Metric Temperature Deg. F - Deg. C 285 140.7 285 140.7 285 140.7 Inlet Flue Gas Flow, actual acfm - Am3/s 2,048,294 966.79 2,048,294 966.79 2,048,294 966.79 Conditions Fly Ash Conc
Slide 53: Current & Future DFGC Applications
CURRENT & FUTURE DFGC APPLICATIONS 53
Slide 54: Summary
ALENTEIEC FUEL TECH
Slide 55: Summary
SUMMARY • In conclusion, in properly designed and implemented DFGC system (at appropriate stoichiometric ratio), ammonia will, in effect, scavenge SO3 thus creating various ammonia salts • While SO3 will be working on improving the fly ash resistivity, the ammonia salts will be working on improving
Slide 56: Flue Gas Conditioning: Summary
FLUE GAS CONDITIONING: SUMMARY NH4HSO4 SO3 (NH4)2SO4 H2SO4 SO3 SO3 H2O H2O NH3 SO3 H2SO4 H2O 56
Slide 57: Questions & Answers
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