Beruflich Dokumente
Kultur Dokumente
10 October 2011
Top Plants:
Six Winning Coal-Fired Plants
ZLD Fundamentals
SCR Hg Removal Co-benefits
How to Design a CCB Landfill
Redirect Fish Clear of Intakes
36
Established 1882 Vol. 155 No. 10
October 2011
ON THE COVER
City Utilities of Springfield, Mo., placed its new John Twitty Energy Center Unit 2 into
commercial service in January 2011. It includes a steam turbine from Toshiba, digital controls from Emerson, boiler island from Foster Wheeler, and dry fluidized bed scrubber and
baghouse from Allied Environmental. Stanley Consultants provided detailed design, cost
estimating, scheduling, and resident engineering services during construction. Courtesy:
Stanley Consultants, photo by Mike Williams
40
44
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PLANT DESIGN
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84 NEW PRODUCTS
COMMENTARY
Web Exclusive
The U.S. Environmental Protection Agency began rolling out its long-anticipated power
plant regulations this year. U.S. Coal-Fired Power Development: Full Employment
for the Lawyers at www.powermag.com examines how some utilities have already
shuttered some older plants, citing the new rules as the cause; some are waiting, hoping that knee-jerk reactions of neighboring utilities will allow them to keep operating
their older plants; and only the lawyers are happy with the result.
www.powermag.com
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After Market
Boilers
Nuclear
SCR
Hitachi Power Systems America, Ltd. 645 Martinsville Road Basking Ridge, NJ 07920
www.hitachipowersystems.us
power.info@hal.hitachi.com
Turbines
SPEAKING OF POWER
Epic Fail
ver the past 18 months, four solar energy equipment companies
have closed their doors. Each
one blamed poor market conditions for
its economic woes, even though each
had fundamental weaknesses that went
unaddressed. It now appears that the
Department of Energy (DOE) did insufficient due diligence before backstopping
one of those four companies, Solyndra,
with a $535 million loan guarantee.
Solyndra announced on September 2
that it was entering Chapter 11 bankruptcy and immediately released the companys more than 1,100 employees, with
no notice. The company opened a massive
$700 million dollar manufacturing facility
in Fremont, Calif., earlier this year using cash from a $535 million dollar DOE
loan guarantee and reportedly $1 billion
in venture capital funding. The Treasury
Departments internal Federal Financing
Bank loaned the money, so a loan guarantee in default is lost cash.
Solyndra joined Hopewell Junction,
N.Y.based Spectrawatt Inc. (an Intel
Corp. spinoff) and Evergreen Solar of
Marlboro, Mass., both of which filed for
Chapter 11 bankruptcy in August. BP
Solar closed its Frederick, Md., plant in
March of last year.
Great Expectations
You may recall that Solyndra was
praised by President Obama as a prime
example of how green jobs were being
created through government backing
of promising renewable energy firms.
During a well-publicized plant visit
on May 26, 2010, the president said,
Its here, that companies like Solyndra
are leading the way toward a brighter,
more prosperous future. He went on to
say that The true engine of economic
growth will always be companies like
Solyndra and that their technology
was game-changing.
The Solyndra technology was far from
innovative, much less game-changing.
Its plan was to produce tubes lined with
thin-film technology solar cells that
are mounted in a flat panel-like rack.
6
P E O P L E
P R O C E S S E S
T E C H N O L O G Y
Power
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2. Made in China. The second reactor of the Ling Ao Phase II nuclear plant started commercial operation in August. Courtesy: Alstom
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24.03.11 15:2
10
AES Solar
K Road Power
NextEra
NRG Solar
663-MW Calico
Solar Farm
Barstow, Calif.
No reason cited.
NRG Solar
Solar Millennium
Solar Millennium
250-MW Ridgecrest
Power Plant
Kern County, Calif.
1,000 MW total
California and Nevada
In August, a
spokeswoman said
the company is also
considering a switch
to PV for projects
near Palen, Calif., and
Amargosa Valley, Nev.
www.powermag.com
Solar Trust of
America
1-GW Blythe Solar
Power Project
Riverside County, Calif.
This Solar Millennium
subsidiarys $2.8 billion
project received a $2.1
billion DOE conditional
loan guarantee
commitment earlier this
year, but in August the
company said the switch
was a response to
favorable conditions in
the PV and commercial
lending markets.
www.ftek.com | 800.666.9688
and Haiyang sites in China. Toshiba, which intends to continue pushing sales of the AP1000 in countries like the UK,
India, and Brazil, is reportedly considering new engineering
partners for future projects, however, and it could invite new
investors into Westinghouse. Several companies have already expressed interest, it has said. Shaw will likely focus on
upgrading the output of existing nuclear plants.
Westinghouse continues to believe that the future of the
nuclear energy industry is robust, and that a significant number of additional new construction projects around the world
will be announced over the next few years, said Dr. Aris
S. Candris, president and CEO of Westinghouse. To further
ensure that we are able to maintain our leadership role in
the successful deployment of new plants, and to fulfill the
expectations of our customers and other stakeholders, we will
continue to identify additional partners and suppliers, including local construction companies with which we can partner while maintaining our collaborative relationship with the
Power Group at Shaw to capture and share best practices.
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2,000-MW Sabiya combined cycle gas turbine facility in June to alleviate tight power supplies and to help meet soaring demand the country
sees each summer. Courtesy: Kuwait Ministry of Electricity and Water
UHE FURNAS one owned by Brazilian utility FURNAS may not emit as
much greenhouse gas as had been previously suggested, a new analysis shows. Located in the middle of the Rio Grande, the UHE FURNAS
reservoir is one of the largest in Brazil. It impounds the Grande River
and has a capacity of 22,590,000,000 cubic meters (18,314,011 acre
feet) and a surface area of 1,473 square kilometers (569 square miles).
Courtesy: FURNAS
POWER Digest
Siemens Gets $1 Billion Order to Build Gas Power Plants
in Thailand. Siemens on Aug. 17 said it received two orders worth $1 billion from Thailand for the engineering, procurement, and construction (EPC) of combined cycle power
plants. The firm will build Chana Block 2 in the province of
Songkhla and Wang Noi Block 4 in the vicinity of Bangkok
with Japanese partner Marubeni. Chana Block 2, an extension to the Chana Block 1, will be the first single-shaft power
plant built in Thailand based on the Siemens field-proven
design, whereas Wang-Noi will be of multishaft configuration.
The two plants, built for state-owned utility Electricity Generating Authority of Thailand, will each have an installed
capacity of about 800 MW and are scheduled to come online
in the summer of 2014.
www.powermag.com
www.proenergyservices.com/service
In addition to EPC, Siemens will supply the main components, namely, an SGT5-4000F gas turbine, an SST5-3000-series steam turbine, an SGen5-2000H generator, all electrical
equipment, an SPPA-T3000 instrumentation and control (I&C)
system, and the ancillary and auxiliary systems. Marubeni will
be responsible for supply of the heat-recovery steam generator, the main transformers and switchgear, and for erection
and installation of the overall plant.
The Wang Noi Block 4 combined cycle power plant will
be built as an extension to the existing complex Wang Noi
Blocks 1 to 3. The plant will be of multi-shaft design consisting of two SGT5-4000F gas turbines, an SST5-5000 steam
turbine, three SGen-1000A generators, the entire electrical
and I&C (SPPA-T3000) equipment, and the ancillary and auxiliary systems.
Thailand is the largest per capita power consumer in Southeast Asiaowing to high consumption by its steel, textiles,
and rubber industriesand currently has an installed power
plant capacity of approximately 39 GW. Demand is expected
to grow at 3.5% per year, and the government has plans to
increase the countrys total installed capacity to 52 GW by
2020. Gas-fired power plants, which already have a major
share of the countrys capacity profile, are expected to supply 5% of the countrys power by 2015. Siemens recently
posted several orders from the country for the supply of 20
industrial gas turbines.
NRG Solar Begins Operations at New Mexicos Roadrunner Facility. NRG Solar, a subsidiary of New Jersey
based NRG Energy, on Aug. 31 began producing power at its
20-MW Roadrunner Solar Generating Facility, a photovoltaic
(PV) project in Santa Teresa, N.M., about 10 miles from El
Paso, Texas. The plant, the first operated by the company
outside California, uses First Solars advanced thin-film PV
solar modules, which are mounted on single-axis trackers.
First Solar, which was the projects EPC contractor, will also
be the operations and maintenance contractor for the 210acre facility. Power generated by the Roadrunner facility will
be sold to El Paso Electric under a 20-year power purchase
agreement (PPA).
Alstom Signs Contract for 125-MW Solar Steam Turbine. Alstom in August signed a contract with U.S. firm Cobra Thermosolar Plants to supply a 125-MW steam turbine
and a generator for a thermal solar plant in Tonopah, Nev.,
using tower technology. The turbine will be delivered in September 2012 and the solar plant will be commissioned by the
end of 2013. The project is the application of an innovative
solar energy storage technology and will produce 500,000
MWh per year to be sold to Nevada utility NV Energy.
Sonal Patel is POWERs senior writer.
www.powermag.com
PROTECTING POWER
PLANT CHIMNEYS
FGD...Soft on
the environment.
Tough on bricks.
Acidic condensate. Positive pressure. Thermal
shocks. Thermal cycles. FGD may be good for the
environment but its tough on the brick lined flues
in your power plant chimney. Fail to protect, and
it will soon be tough on your maintenance budget.
1. World record holder. JEA repowered two old steam boilers at the Northside Generating Station with circulating fluidized bed
(CFB) boilers. When installed in 2002, the two CFB boilers were the
largest in the world. The steam turbine portion of the plant remained
unchanged. Courtesy: JEA
Ash recirculation
due to lack up
upward air flow
Tube shelf
agglomeration
18
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in different operating environments have different failure mechanisms, making some of them more suited than others for inspection by APR. Finned tube heat exchangers are a typical example
of heat exchangers particularly conducive to APR inspection.
The reason APR is particularly useful on finned tube heat exchangers is that it is purely an internal pipe inspection method.
This is a limitation where tubes are susceptible to external damage by corrosion or abrasion from support plates. In finned tube
exchangers, however, the tubes often rest on top of each other,
supported by the fins. There are no support plates, and in cases
where the external fluid is forced air, there are no hostile chemicals on the exterior of the tubes.
Dual-cycle geothermal power plants often employ this type
of heat exchangers. In this type of geothermal plant, hot brine
heats an organic liquid having a low boiling temperature, turning it into vapor. This higher-pressure gas expands through the
turbine, producing power. The lower-pressure gas is then condensed using finned tube heat exchangers (condensers in this
case), which are cooled by air forced across the highly finned
heat exchanger tubes by large fans. Thoroughly inspecting these
heat exchanger pipes has been problematic, until now.
How APR Works
The theory behind APR is to inject a wideband acoustic pulse into
a pipe. This pulse acts as a form of virtual probe. As long as
the pulse encounters no discontinuities, it continues to propagate down the tube. Whenever a discontinuity is encountered
such as a blockage, expansion (due to wall loss, for example), or
holea reflection is created. The reflected waves propagate back
Impinging pulse
Reflection from
a constriction
Reflection from
a dilation
Reflection from
a leak
down the tube, where they are recorded for analysis (Figure 5).
The ultimate purpose of tube inspection should be to examine
tubes as rapidly as possible and then analyze the measurements
both rapidly and using objective criteria. Keeping this in mind,
APR is very well-suited to this task on both counts. The pulse
acting as a probe travels through the tube at the speed of sound,
resulting in inspection rates much faster than those possible
with other techniques. Measurement of a single tube takes only
several seconds, and there is no physical probe to push through
the tubes or become stuck. The resultant measurements can then
be analyzed by appropriate signal processing software, which is
faster and more objective than human analysis.
www.powermag.com
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m_140
<Noise top>
m_139
<Noise bottom>
<ThrPB> 25%
<ThrPB> 20%
<ThrPB> 15%
<ThrPB> 10%
<ThrPB> 5%
<Noise top>
<Noise bottom>
m_140
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15.1 15.2 15.3 15.4 15.5 15.6 15.7 15.8 15.9 16.0 16.1 16.2
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CIRCLE 15 ON READER SERVICE CARD
Finally, observing one of the measurements along with the blockage thresholds
(Figure 7) shows there is a blockage at
15.3 meters, blocking about 23% of the
cross section.
n
rGe 242
e
w
Po th# 4
Boo
Midwesco is committed to helping customers respond to todays environmental challenges while improving
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SymphonyTM Plus is the new generation of ABBs total plant automation for
the power and water industries. Designed to maximize plant efficiency and
reliability through automation, integration and optimization of the entire plant,
Symphony Plus offers a simple, scalable, seamless and secure solution.
Tune to Symphony Plus and experience the power of a well-orchestrated
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13/04/11 09.22
The best explanation for this condition was that water residues
had been left in the tubes when the condenser was put into service.
The source of these residues was assumed to be the hydrotesting that
had been carried out upon installation, three years earlier.
At this point the operator was left with two possibilities: the
very expensive prospect of replacing the problematic condensers
or cleaning out the corrosion. The operators main concern was
that, after cleaning, the tubes would be shown to be in such
bad condition that they would have to be replaced anyway. The
decision was made to first clean out a single condenser unit and
inspect the tubes.
The leaking condenser was hydroblasted and then inspected
by a commercial service provider, using APR. Several additional
holes were found, as were tubes with severe pitting. However,
the majority of tubes were in satisfactory condition.
In view of the condition of the tubes after cleaning, and the
rapid inspection time available with APR, the operator made two
major decisions:
4.5
3.6
2.7
1.8
0.9
0.0
0.9
1.8
2.7
3.6
4.5
5.4
<ThrPB> 5%
<Noise top>
<Noise
bottom>
m_142
15.2
15.4
15.6
15.8
16.0
16.2
16.4
16.6
16.8
17.0
17.2
17.4
26
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Since 1903, Roberts & Schaefer has been a world leader in the
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Whether its complete system development, upgrades,
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its excess power, because that would impose extra costs on its
regular power customers. Instead, BPA decided to use its authority over the grid to protect its power customers from additional
costs, and to push the responsibility for excess hydropower onto
other generators in the region, primarily wind generators with
government-provided incentives. Because no one argued that
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TOP PLANTS
Coyle, plant manager told POWER in August. The plant provides jobs and a tax
base to the local community, and we work
hard to be a good corporate neighbor.
As one example of the facilitys efforts,
Coyle explained that Coffeen Lake is
owned by Ameren, but Ameren has a lease
agreement with the Illinois Department of
Natural Resources to manage it, and the
lake is considered a wonderful year-round
hunting and fishing resource.
Visitors to Coffeen Lake can find a diverse range of wildlife. Muskrats, turtles,
herons, and mussels can be seen in or near
the water. Bobwhites, coyotes, whitetailed deer, black rat snakes, red-tailed
hawks, and blue jays are also common to
the area.
www.powermag.com
Plant Upgrades
In February, the plant began a major outage
that involved replacing all 14 of the 1970sera cyclones in the Unit 2 boiler and several
other plant improvements. The plant returned
to service in May.
Coffeens Unit 1 came online in 1965.
The original engineering firm was Sargent
& Lundy, and Alberici was the original construction company. Unit 2 went commercial
in 1972 with the same engineering and construction partners.
New environmental control systems
have been installed on both units during the
past decadebringing to more than $1 billion the investment made in environmental
controls at this site alone. (Additionally,
in the past few years, AER has spent more
W E S T I N G H O U S E E L E C T R I C C O M PA N Y L L C
TOP PLANTS
than $1 billion on environmental improvements on scrubbers, precipitators, new
landfills, and mercury reduction technologies at its other power plants.) In 2009 and
2010, scrubbers were installed on Coffeen
Units 1 and 2. These sophisticated systems
help to significantly cut the plants sulfur
dioxide (SO2) emissions and also reduce
mercury emissions. Reducing SO2 emissions by more than 90%, the scrubbers are
designed to redirect the outlet stack gas
through a spray-tower scrubber design,
where the gas mixes with water, a 20%
limestone mixture, and compressed air.
The SO2 in the flue gas then reacts with the
limestone to produce a gypsum by-product
that can either be sold for commercial use
or placed into a landfill for disposal.
In addition to scrubbers, other recent
environmental improvements at Coffeen included an electrostatic precipitator
(ESP) upgrade on Unit 1 and a new ESP on
Unit 2. Though ESPs have been around for
many years, the ones installed at Coffeen
offer the latest improvements that make
them very effective in ash removal. Recent
environmental projects also have included
installation of new selective catalytic reduction (SCR) systems on both units and
the addition of other environmental control equipment and systems that support
cleaner water and air.
Alberici, the construction company in
charge of the project, handled the mechanical installation of two large, state-of-the-
1. Keeping things under control. In the control room at Ameren Energy Resources
Coffeen Plant, in central Illinois, operations and engineering personnel discuss the operating
parameters of one of the newly installed scrubbers. Courtesy: Ameren Energy Resources
Facility Overview
Coyle summed up Coffeens efficiency rate
by pointing out that we expect to produce
more than 7 million MWh net per year.
The heat rate of Unit 1 is approximately
10,200 Btu/kWh; Unit 2 is about 9,800
Btu/kWh.
The facility has upgraded its rotors over
the past decade, with the most recent improvement being a Toshiba high- and intermediate-pressure turbine installed in Unit
2 in 2010. High-efficiency turbines have
been installed in both units, which have
allowed us to increase generation output
for the same coal use, Coyle said. This
has the benefit of offsetting the increased
auxiliary load required by the new scrubbers by implementing energy efficient
projects.
The expectation is that future equivalent
availability will be >90% and the capacity factor will be nearly the same level to
take advantage of the units low-cost, lowemission capability, Coyle explained.
The plant is operated and maintained
by 170 full-time employees (Figure 1).
There is a strong emphasis on plant safety,
which has dramatically reduced accidents
in recent years. Coyle pointed out that the
plant had zero accidents through the first
half of 2011.
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TOP PLANTS
Planning Ahead
Later in 2005, Alstom Power was awarded
contracts to supply equipment for a new $1
billion, 750-MW coal-fired unit: Spruce 2,
at the utilitys Calaveras Power Station.
Under the contracts, Alstom supplied a
new coal-fired boiler as well as an AQCS,
resulting in a plant that is one of the cleanest in the U.S. in terms of SOx, NOx, and
particulate emissions.
TOP PLANTS
There are also four other units at the
site: the Sommers power plant (two gasfired boilers) and the Deely power plant
(two coal-fired units).
The new unit is located next to Spruce
1, a 550-MW coal-fired unit that began
operation at the end of 1992 and was designed with provisions for an additional
unit. Those provisions for a future Spruce 2
included much of the necessary infrastructure, such as the water treatment building, machine shop, coal-handling supply
conveyors, and scrubber wastehandling
equipment. That approach saved as much
as $300 million in construction costs for
the new unit.
The process of obtaining a permit from
the Texas Commission on Environmental
Quality to build Spruce 2 was challenging
but ultimately successful. To obtain the
permit, CPS Energy proposed emissions
levels that were stricter than those established for SOx and NOx at the time for
other plants in Texas.
The project was handled by Calaveras
Power Partners LP (CPP), a consortium of
Black & Veatch, TIC (The Industrial Company), and Zachry Construction. Following
an evaluation of bids for the project, CPP
awarded Alstom the contract to supply the
boiler in September 2005 and the contract
for the environmental control equipment a
month later.
Under the first contract, Alstom was responsible for delivering the complete boiler
island and the selective catalytic reduction
(SCR) equipment. The scope of supply included fans, motors, boiler water circulation
pumps, valves, coal mills, bottom ash equipment, and air heatersessentially, all equipment connected to the air heater outlet.
Under a separate contract for environmental control equipment, Alstom supplied a reverse gas fabric filter to reduce
particulates and a wet flue gas desulfurization (FGD) system to remove SO2, hydrogen chloride, and hydrogen fluoride.
A reverse gas fabric filter removes particulate emissions. The fly ash collected is
reused in the cement industry, while the
bottom ash is used for roadbed and other
construction applications; consequently,
there is very little disposal of ash waste
products on site. CPS Energy has been
meeting its particulate emissions and opacity targets since the start of operation.
Upon leaving the baghouse and induced
draft fans, the flue gas enters a wet FGD
for the final stage of cleaning. The wet
scrubber is an open spray tower, wherein
the reactive slurry from the tank portion of
the vessel is recirculated to the top of the
tower and sprayed down onto the gas using a header with a series of nozzles. SO2
removal occurs as the flue gas is directed
up and through a series of headers or spray
levels that are spraying the limestonebased reactive slurry. The desulfurized
gas exits the tower and goes to the stack.
The solid by-product from the scrubber
is gypsum. The wet FGD system has also
achieved its design target emissions of less
than 0.06 lb/MMBtu SO2, well below the
levels required by the air permit.
The new unit uses cooling water taken
from the man-made Calaveras Lake. From
the outset, the control room was designed
to house controls for both Spruce units.
Operators can manage operation of the
boiler, turbine, scrubber, and waste-handling system of each unit from this common control room.
www.powermag.com
35
TOP PLANTS
City Utilities of Springfield elected to add a 300-MW coal-fired plant to its fleet to
meet rising demand for electricity. It was the first coal plant constructed by the
utility since 1976. An extremely competitive construction market required the
utility to adopt new contracting practices to meet a tight project schedule, an
approach that proved very successful. The $555 million plant commissioned
in January 2011 is expected to cover system growth at least through 2024.
By Dr. Robert Peltier, PE
got the power to prove it. A four-year timelapse video of the plants construction is available at www.tinyurl.com/cus2010.
The Emerson logo is a trademark and service mark of Emerson Electric Co. 2011 Emerson Electric Co.
Ovation and the Ovation logo are trademarks of Emerson Process Management.
E M E R S O N . C O N S I D E R I T S O LV E D .
TOP PLANTS
1. Same plant, new name. After completion of Southwest 2, City Utilities of Springfield
in May renamed its energy complex the John Twitty Energy Center in honor of the utilitys retired general manager. The energy center has a combined gross output of 503 MW. Unit 2, the
larger structure on the left, is rated at 300 MW. The 203-MW Unit 1, the smaller structure on the
right, was completed in 1976. Courtesy: City Utilities
struction contractors on market pricing for materials and equipment and on labor availability
and productivity. City Utilities served as its
own construction manager for the project.
A hybrid contracting approach was used
for plant construction:
Challenges Abound
Compliance with all the environmental permits is often the critical path for these large
construction projects. For JTEC Unit 2, the
air permit required CU to begin construction prior to November 2006 or the permit
would expire. Because the air permit defined
the stack height and diameter, the foundation
was designed based on past project experience. As seen in the video, construction began with drilling about 20 piers for the stack
foundation, each more than 25 feet deep,
followed by a continuous pour 10-foot-thick
and 80-foot-diameter chimney foundation.
Procurement of major equipment and commodities, such as steel, took place in 2006
when marketplace activity was at historic
highs and contractors had large backlogs. For
example, when soliciting bids for the boiler island installation, of the three firms qualified to
bid, two did not submit proposals. A negotiated contract with the remaining firm resulted.
Early procurement of major equipment,
along with open book construction contracts, allowed significant owner involvement
in the equipment selection and subcontracting processes. Often, nonstandard contracting
approaches were required, such as accepting
bond limits, incorporating target pricing for
payment structures, and negotiating lump sum
contracts with variable risk-sharing provisions.
The cost risk was shared with the major conwww.powermag.com
Treated municipal wastewater from the Southwest Wastewater Treatment Plant (SWTP) is
used for cooling water makeup and wet flue gas
desulfurization sprays, saving approximately
five million gallons per day of water that would
otherwise have been supplied from underground
aquifers. The water is pumped from SWTP,
located about a mile away, through a 20-inchdiameter pipe to the plant. Water is stored on site
in a 2.7 million gallon storage tank. The water
quality, especially the chloride levels, required
using SeaCure condenser tubes and titanium
plates in other plant heat exchangers.
Emerson supplied its Ovation distributed
control system for Unit 2. The plant makes extensive use of digital bus technologies with nearly 4,200 I/O points, more than 500 Foundation
fieldbus devices, and more than 100 Profibus DP
devices. The plant also uses Emersons Intelligent Device Manager to streamline installation
and the configuration of each field device during
start-up. In addition, the AMS Device Manager
provides diagnostic and predictive maintenance
information during plant operation.
Although not part of this project, Unit 1
controls were also recently upgraded to Emersons Ovation Expert digital controls. The
new control room constructed for Unit 2 included sufficient room to house the control
panels from both units.
The plant was designed using 3-D modeling software. This allowed a virtual check for
interferences, particularly between structural
steel, electrical cable tray and conduit, and
piping. The software allowed users to take a
virtual walk through the facility prior to beginning construction. Building information
such as equipment tag numbers, valve numbers, and object specifications, were also collected in the 3-D model for future use.
Your Single-Source
System Provider
www.williamscrusher.com
CIRCLE 23 ON READER SERVICE CARD
TOP PLANTS
In April 2008, AES Philippines purchased the Masinloc coal-fired power plant in
Zambales Province in the Luzon region. Originally constructed in 1998 as a twounit, 600-MW plant, the facility uses coal from a variety of sources in the Pacific
Rim. After AES finished overhauling much of its equipment, the expanded 660MW (gross) plants availability increased from 48% to 74%, which enabled net
electricity production to jump by 129% by 2010.
By Angela Neville, JD
Clean on arrival.
Guaranteed.
2011 ConocoPhillips Company. ConocoPhillips, Conoco, Phillips 66, 76, and their
respective logos, and Diamond Class are trademarks of ConocoPhillips Company in
the U.S.A. and other countries. T3-CPL-1428
CIRCLE 24 ON READER SERVICE CARD
TOP PLANTS
1. Pacific Rim powerhouse. The Masinloc coal-fired power plant is located about 250 kilometers (approximately 155 miles) northwest of Metro Manila and covers about 137 hectares (approximately 338 acres), including 11 hectares of land reclaimed from the sea. Courtesy: AES Corp.
Operations Overhaul
When AES bought the Masinloc Plant,
which consisted of two 300-MW units, from
PSALM, it was 10 years old. The plants history of inadequate maintenance and capital
expenditures, which were further compounded by poor operating practices, had placed the
facility in a poor state of repair, and it faced
significant operational limitations. These issues resulted in high equivalent forced outage rates, low equivalent availability factors,
and low net capacity factors.
Prior to the plants turnover to AES, the
maximum net generation achieved by the
Masinloc Plant was 433 MW on a nameplate
capacity of 600 MW. Given the plants operational history, AES saw an opportunity to initiate a rehabilitation program to transform the
plant and substantially increase its output. The
rehabilitation program had two phases: The
first focused on mechanical and major rotating
equipment, and the second focused on boiler
rehabilitation and environmental controls.
Efficiency and heat rate improvements
were among the most notable achievements.
The plants overall efficiency increased by
13%, which reduced the amount of fuel oil
used for start-up. And the AES team reduced
the plants overall heat rate by 1,500 points
from the time AES took over the facility,
42
Promoting a Culture of
Empowerment
To make the rehabilitation of the Masinloc
plant sustainable, the AES management team
improved the technical skills of its workers
while fostering a culture of empowerment.
The company led teams through job scope
and skills analysis and equipped them with
www.powermag.com
TOP PLANTS
The new 665-MW Plum Point Energy Station is energizing the Arkansas Delta,
an area that is ready to supplement its farming heritage by promoting new jobs
that offer residents a higher standard of living. But first, the plants construction
team had to overcome a number of significant challenges related to building a
facility in the New Madrid fault zone.
By Angela Neville, JD
Courtesy: Black & Veatch
TOP PLANTS
1. From the bottom up. A worker
stands beneath the header where the downcomers terminate at the bottom of Plum
Points pulverized coal boiler. Courtesy: Black
& Veatch
Plant Profile
People Power
The construction team had to meet the various regulatory environmental restrictions
Toshiba manufactured the steam turbines and shipped them to Osceola from
Tokyo. The steam generator was also
manufactured by a Japanese company,
IHI, which has utilized manufacturing
facilities in a number of areas in Southeast Asia. Alstom provided the air quality
control system scrubber and the baghouse.
Thermal Engineering Inc. manufactured
the condenser, which was shipped from
Missouri. The transformers were manufactured in Korea by Hyundai Heavy Industries, a major supplier to the power
industry. Emerson provided its state-ofthe-art Ovation distributed control system. Black & Veatch utilized its global
www.powermag.com
TOP PLANTS
TOP PLANTS
a variety and combination of fuels, including
domestic bituminous coals, Columbian coal,
and petcoke. Since 2004, combustor modifications allowed burning 100% petcoke in up
to eight burners (two pulverizers) and coal
in the remaining 16 burners. The high vanadium and sulfur in the petcoke, high arsenic
and low calcium in the domestic coal, and
high silica (up to 18% ash) in the Columbian
coke made design and selection of the SCR
problematic.
High arsenic levels can accelerate the
rate of catalyst deactivation, and sulfur
concentration determines the catalyst minimum operating temperature that is a factor
in the production of visible SO3 emissions.
Increased vanadium in the fuel (vanadium
is also an active metal in the catalyst) will
increase the production of SO3 emissions,
further complicating the already complex
SCR selection process. Further confusing the fuels selection, at SJRPP fuels are
direct-bunkered (a specific fuel goes to a
specific set of burners, as the fuels are not
mixed prior to burning), meaning that no
benefit could be realized for any individual
fuel characteristics that might cancel out
when blended with other fuels with different characteristics.
Given the large number of combinations
of fuel mixtures possible, the only definitive approach to characterizing combinations of fuels and their interactions was to
perform pilot testing. Therefore, a series
of baseline or characterization tests were
designed to establish actual flue gas operating conditions at various plant operating
conditions.
In February 2006, Clean Air Engineering began tests to define flue gas flow and
temperature distributions, emission concentrations, boiler operating conditions,
and fuel and ash analyses at nine different
1. Double play. Two 50%-sized SCR reactor modules were placed east and west of the
boiler-airheater centerline. Also included were
double isolation dampers on both the inlet and
outlet and large particle ash screens on the inlet of each module. Courtesy: Black & Veatch
Project Challenges
Construction of the two SCR additions
was completed in just 23 months, for both
units. Given the compact area of the site
and poor access to the space between the
boiler and stack, the SCR reactors were
positioned to the east and west of each
boiler-airheater center line, two 50% reactor modules per unit (Figure 1). In addition, locating SCR steel support structures
directly behind each boiler, in a tradition48
www.powermag.com
Diamond Powers
PLANT DESIGN
for at: w e r
ter nar p o
gis bi m /
R e We . c o
EE c h
FR . h a
w
ww
There are only two dates
you need to remember once a year
866-450-4248 www.hach.com/K1100
1M116DL
PLANT DESIGN
bulk of the impinged fish. These smaller,
weaker swimming fish are unable to escape
the intake current and are drawn in to the intake screen.
Technologies growing in favor are those
that use behavioral modification, a system
that uses stimuli such as electricity, sound,
light, and air bubbles. The results obtained at
several power stations and other water intakes
over the past 10 years have proven such technologies to be effective in protecting many of
the juvenile or mature fish species.
Multi-Purpose Fence
The bio-acoustic fish fence (BAFF) system
is a novel approach to blocking fish from impinging on intake structures. The pneumatic
nonphysical barrier system introduces sound
and, in some cases, light into a bubble curtain. This wall of sound, light, and bubbles is
very effective in guiding and deflecting fish.
Sound Fence. The BAFF system consists of series of sound projector arrays
(SPA) connected to a source signal generator via a series of amplifiers by special underwater cables. The sound projectors are
designed to transmit sound into water for
varying water depths.
The difference in effectiveness of the
BAFF is attributed to differences in specie
sensitivity, principally the anatomy of the
1. Fish hearing test results. The reference for the figure is a relative loudness value
of 1.0, which translates into 0 dB as the baseline. Because the scale is logarithmic, at 10 dB,
the relative loudness is reduced to 0.5 of the baseline; at 20 dB, 0.25 and so on. A sound level
measurement of 1 pascal is equivalent to a sound pressure level (SPL) of 94 dB, the volume
level we actually hear. This graph allows us to estimate the SPL hearing threshold of various fish
species for different frequencies. For example, cod can detect very low sound levels in the 100
Hz to 250 Hz frequency range. Source: A.D. Hawkins, The Hearing Abilities of Fish, Hearing
and Sound Communication in Fishes, 109-33 (Springer-Verlag, 1981).
+20
Salmon
+10
array with a high-intensity light bar with a curtain of bubbles forms an effective fish fence.
Source: Ovivo USA LLC
10
Catfish
20
Cod
Dab
30
40
50
60
70
30
50
100
200
500
1,000
2,000
5,000 10,000
Frequency (Hz)
52
www.powermag.com
PLANT DESIGN
3. Effective barrier. This photo shows the fish barrier being installed before the cooling
water intake at Ontario Power Generations Lambton Power Station. Courtesy: Ontario Power
Generation, Kinectrics Inc.
from gizzard shad impingement. Following the initial demonstration, the plant
installed a system consisting of 18 SPA
and nine high-intensity light bars. A large
number of gizzard shad were present in
the discharge during testing and were concentrated in the dimensions of the thermal
plume. It was reported that these fish were
the source of fish impingement at Lambton, especially during winter months.
Gizzard shad reside in the warm cooling
water discharge during winter and leave in
spring (April to May). In tests conducted
during the day and at night, the SPA and
high-intensity light barrier were effective
in deterring the gizzard shad (Figure 3).
Your Vision
Is Our Mission
Taggarts proven and innovative EPC solutions deliver increased efficiencies to clients
worldwide in the areas of design, construction, commissioning and operation of mineral
processing plants, bulk material handling facilities, ports and terminals, blending and
storage systems and many more.
Call or visit our website to learn how Taggart can help accelerate your return
on investment and execute your projects on-time and on-budget.
NORTH AMERICA | SOUTH AMERICA | AFRICA | ASIA | AUSTRALIA
CORPORATE HEADQUARTERS
4000 Town Center Blvd.
Canonsburg, PA 15317
Telephone: 724-754-9800
www.taggartglobal.com
2011 Taggart Global LLC
www.powermag.com
53
PLANT DESIGN
4. Scale-model testing. The U.S. Bureau of Reclamation tested a scale model of the Head
of Old River located in the Sacramento Delta to determine the effectiveness of the bio-acoustic
fish fence at its Hydraulic Laboratory in Colorado. Courtesy: U.S. Bureau of Reclamation
effectiveness of the BAFF using SPA, highintensity light bars, and an air bubble curtain
was tested (Figure 4).
The data collected from the USBR flume
testing was used to design a full-scale 112-
Dr y
Sorbent
Injection
www.nol-tec.com
CIRCLE 30 ON READER SERVICE CARD
54
www.powermag.com
PLANT DESIGN
6. Modular design. A segment of the bio-acoustic fish fence being installed. Courtesy:
Ovivo USA LLC
7. Altered paths. The location of the bio-acoustic fish fence is illustrated by the straight line.
The yellow line represents the travel path of the tagged smolts with the barrier turned on (left)
and turned off (right). Courtesy: Ovivo USA LLC
Potential is limitless.
An idea has no momentum until talented people start chasing it. Its then that
one begins to glimpse whats possible, and the future begins to take shape.
Today, we are thousands of people sharing ideas, dedicated to finding new
ways to meet the needs of an ever-demanding Power sector. Which is why,
when it comes to nuclear, natural gas, coal, renewables, hydroelectric and
electric delivery systems, more people are turning to us to get it done.
We are URS.
POWER
INFRASTRUCTURE
FEDERAL
INDUSTRIAL & COMMERCIAL
URSCORP.COM
For more information, please contact 609.720.2000.
www.powermag.com
55
WATER TREATMENT
n most power plants, the largest wastewater producer is the cooling water system.
Historically, natural evaporation of the
cooling tower blowdown from holding ponds
has been very successful, particularly in the
western U.S. This approach to waste liquid
disposal is a simple but effective example of
a zero liquid discharge (ZLD) system. The
downside is that the water is permanently lost
from the system through natural evaporation,
and the remaining residue must be periodically cleaned from the pond.
Because cooling tower blowdown is relatively dilute, generally less than 10,000 mg/L
total dissolved solids (TDS), reverse osmosis
(RO) membranes are often used to pre-concentrate the cooling tower blowdown prior to
concentrating the liquid in an evaporator; the
remainder is reduced to solids in a crystallizer. The salts present in cooling tower blowdown, for example, are usually composed of
sodium sulfate and sodium chloride with
small quantities of calcium, magnesium, sulfate, and bicarbonate. All of these salts can be
readily crystallized by evaporation.
However, wastewater from wet flue gas
desulfurization (wet FGD) systems and integrated gasification combined cycle (IGCC)
plants contains highly soluble salts, such as
calcium and ammonium chlorides, and certain heavy metal salts, which are not so easy
to crystallize by evaporation. Conventional
ZLD evaporation-crystallization processes
for wet FGD and IGCC waste streams require
clarification and extensive pretreatment. Usually, the wastewater must be treated with lime,
soda ash, and other chemicals to replace the
calcium, magnesium, ammonium, and heavy
metal ions with sodium ions so that a crystalline solid can be produced. The pretreatment
equipment and chemicals increase the ZLD
system footprint as well as the capital cost
and system maintenance requirements.
Burning or gasifying coal or petcoke produces a gas that can contain sulfur dioxide,
56
WATER TREATMENT
FGDs, for example, the option of using RO
membranes must be eliminated because the
osmotic pressures rise beyond accepted limits due to the high concentration of dissolved
salts (30,000 to 60,000 mg/L). Once the
dissolved salt concentration in wastewater
reaches a few percent by weight, evaporation
must be used to achieve further recovery of
water and concentration of salts.
off dissolved carbon dioxide from the alkalinity reduction, dissolved oxygen, and any
other non-condensable gases (the red vertical
vent). Venting these gases reduces the potential for corrosion of the evaporator vessel.
Most of the water evaporation occurs in a
falling film evaporator (inside the brine concentrator vessel) that is seeded with calcium
sulfate to minimize scale formation. Wet
FGD wastewater is typically saturated with
calcium sulfate, which will tend to precipitate and form scale on the evaporator tubes.
When calcium sulfate seed crystals are present, the dissolved calcium sulfate precipitates
preferentially on the seed crystals rather than
the evaporator tubes.
The process also requires electricity to drive a mechanical vapor compression
1. Evaporation process. Most of the water evaporation occurs in a falling film evaporator (inside the brine concentrator vessel) that is seeded
with calcium sulfate to minimize scale formation. The process also requires a lot of electricity to operate the vapor compressor, about 18 to 35 kWh
per metric ton of water evaporated. To minimize the size and cost of the vapor separator and compressor, evaporation occurs at atmospheric pressure. The process flow diagram and a photo of the system are shown. Source: HPD LLC
NCG vent
Deaerator
Brine
concentrator
Chemicals
Compression
device
Feed
Concentrated
brine
Level
tank
Feed tank
Recovered water
Feed preheater
Recirculation
pump
Seed
recycle
2. Crystallizer process. The falling film evaporator will concentrate wastewater but will not crystallize large quantities of dissolved salts, so
additional processing is required. A crystallization of the solids occurs in the forced-circulation evaporator-crystallizer. The remaining solids-heavy
waste stream is then sent to a solids dewatering system to remove any remaining water. The process flow diagram and a photo of the system
are shown. Source: HPD LLC
Steam
Crystallizer
vapor body
NCG vent
Surface
condenser
Cooling water
Recovered
water
Crystallizer
heater
Recovered
water
Feed
Dewatering
device
Recirculation
pump
Solids to
disposal
Crystallizer
feed tank
www.powermag.com
57
WATER TREATMENT
58
A Lower-Cost Approach
On projects where the use of a crystallizer
is not economically feasible, a falling film
evaporator will recover 75% to 95% of the
water and concentrate the wastewater that can
then be sent to an evaporation pond. If your
project requires a full ZLD system, there are
several options to consider when exploring
ways to handle the remaining 5% to 25% of
3. Depressed boiling point. This figure illustrates the relationship of the boiling temperature for pure calcium chloride solution against its solubility curve at atmospheric pressure.
As the weight percentage of the calcium chloride increases in solution, the boiling point of the
solution rises. This fundamental property of salt solutions is an important design parameter.
Source: HPD LLC
180
356
CaC12 H2O
& solution
160
320
140
284
Boiling point
120
248
CaC12 2H2O
& solution
100
212
80
176
60
0
20
Solution & ice
40
10
50
68
60
20
104
40
60
140
CaC12 4H2O
& solution
Temp. (F)
Solution
CaC12 6H2O
& solution
At this high temperature, calcium chloride, like magnesium chloride and ammonium chloride, undergoes hydrolysis in water;
that is, it releases hydrochloric acid that will
aggressively attack steel. The rate of hydrolysis increases with the temperature, so materials of construction for the evaporator vessels
and heat transfer surface must be carefully
selected to resist the extremely corrosive nature of these salts at high concentrations and
temperatures. Experience shows that suitable
corrosion-resistant materials at these temperatures and concentrations are very expensive
noble alloys, such as palladium-alloyed titanium and high nickel-chrome-molybdenum
alloys. The requirement for such expensive
materials makes the use of a final crystallizer
economically challenging in most wastewater ZLD applications.
Temp. (C)
70
32
4
40
80
WATER TREATMENT
U
N I T E D STATES
STATES
UNITED
CCANADA
ANADA
SSWEDEN
WEDEN
Silos
Wood Hogs
Disc Screens
Open Storage
Closed Storage
Truck Dumpers
Chain Conveyors
Bucket Elevators
Screw Conveyors
Screw Reclaimers
Pneumatic Conveying
CANADA: Vancouver, BC
Jeffrey Rader Canada
Unit 2, 62 Fawcett Road
Coquitlam, BC V3K 6V5 Canada
Phone: 604.299.0241
Fax: 604.299.1491
SWEDEN: Stockholm
Jeffrey Rader AB
Domnarvsgatan 11, 163 53 SPNGA
Stockholm, Sweden
Phone: +46 8 56 47 57 47
Fax: +46 8 56 47 57 48
www.powermag.com
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FOR PAS-55
COMPLIANCE.
AGILE EAM.
Rate payer organizations, investors and stakeholders need the most bang for their buck, and
are already asking about PAS-55, the new standard for asset lifecycle management. But only
the most agile enterprise asset management (EAM) software will let you comply with this
mandate. Only IFS Applications is comprehensive enough for PAS-55 but agile enough to
implement and reconigure with minimal business disruption. So your energy assets can be as
agile as your thinking.
WATER TREATMENT
the need to pretreat the feed brine to the ZLD
process. Eliminating pretreatment avoids solids settling and filtration equipment, sludge
dewatering equipment, and chemical feed/
storage facilities, substantially reducing the
footprint of the overall water treatment facility. It also avoids producing a sludge waste
product that is expensive to dewater and dispose in a landfill.
By operating under vacuum, the boiling
temperature of the solution is reduced from
that at atmospheric pressure, and a solid can
be obtained at a relatively low concentration.
For example, the BPR is also lower when
operating under vacuum at low temperature:
At 75% calcium chloride the BPR is 135F,
but at 56%, the BPR is only 56F. Therefore, a
saturated solution of calcium chloride (58%
by weight) will boil at 140F if the vapor pressure is maintained around 0.5 psia, which is
well within the capability of typical industrial vacuum systems. The BPR of saturated
calcium chloride solution at these operating
conditions is 60F. This means that the water
vapor that evaporates from the solution will
be 60F less than the boiling temperature of
the solution, or 80F.
Lime
Mix tank
Polymer Soda ash
Clarifier
To evaporator
Feed
Seed sludge
Underflow
Mix tank
Underflow
Filter press
Thickener
5. CoLD crystallizer. HPDs new crystallizer is designed to operate at low temperature and pressure. The heat required to boil the solution
and the cooling necessary to condense the water vapor are supplied by a closed-cycle heat pump. The process flow diagram and a photo of the
system are shown Source: HPD LLC
Refrigerant
Crystallizer
vapor body
Vacuum pump
Vapor
Refrigerant
compressor
Surface
condenser
Crystallizer
heater
Recovered water
Recirculation pump
Dewatering
device
Solids to disposal
Expansion valve
Crystallizer
feed tank
Feed
62
www.powermag.com
WATER TREATMENT
6. Final results. The low-temperature (131F) crystallization of typical wet FGD purge water
(left) produces high-quality distilled water and a stable solid suitable for landfill disposal (right).
Courtesy: HPD LLC
into a much less aggressive solution, so highnickel or highmolybdenum alloy construction materials are not required.
Laboratory testing has proven the effectiveness of this process on typical wastewaters containing highly soluble salts. The
solution depicted in Figure 6 is that of a typical wastewater from a coal-fired power plant
wet FGD system. After evaporation at low
temperature (131F), the wastewater was sep-
63
POWER VIEWS
he short-fused deadlines, extent of coverage, and complexity of new air emissions regulations proposed by the U.S.
Environmental Protection Agency (EPA)
have been cited by several utilities as the reason for recently announced plant closures.
Heres how the Edison Electric Institutes environmental point man sees the situation.
The Utility MACT rule will create national emission standards for HAPs under section
112 of the Clean Air Act (CAA). The EPA
proposed its MACT rule in March 2011, and
the agency is scheduled to put the rule into
final form in November 2011.
The new rule will affect almost all of the
countrys existing coal- and oil-based generating unitsapproximately 1,350 boilers at
525 power plants. Once the rule is issued,
power generators will have up to three years
to install the necessary emissions control
technology. They must reduce their HAPs
emissions to a level equal to or better than
the average emissions of the best-performing
12% of the plants for which the EPA has
emissions data. For those planning to build
new coal- or oil-based generating units,
planned emissions must be based on the bestperforming existing source.
POWER VIEWS
What also has to be taken into consideration when determining how much time
it will take to install the necessary controls
is that utilities schedule power plant maintenanceincluding retrofits and installation of environmental controlsduring the
spring and fall months. This is because peak
demand on their system generally occurs
during the summer and winter months, and
electric utilities must have enough generation facilities online to meet the maximum
demand on their systems. As a result, the
majority of utilities will not be able to work
year-round to install control technologies to
reduce mercury and HAPs.
have begun exploring methods for capturing and storing carbon emissions.
The EPAs Utility MACT is as complex
as it is far-reaching. With greater flexibility in complying with it, we believe that
the new MACT rule will achieve its objectives, while working to lower compliance
costs, increase system reliability, and preserve valuable economic resources.
Dr. Robert Peltier, PE, POWERs editor-inchief, conducted and edited this interview.
to consider extensions on a unit-by-unit basis. But the number of generating units needing additional time likely will be sufficiently
large that a case-by-case review of individual
requests for extensions actually could delay
overall compliance.
Given these realities, we plan to ask the
president to issue an executive order using
the CAA exemption authority for power
plant owners or operators who are unable
to comply with the Utility MACT requirements within four years (the standard threeyear compliance period plus the EPAs
optional one-year extension). We will ask
the president, or any designated agency or
department, to grant these extensions in
the instances where a utility is making a
diligent, good-faith effort to comply but
the control technology is unavailable, or
in those instances where the appropriate
national, state, or regional grid operator,
North American Electric Reliability Corp.,
or state regulators certify that an extension
of time is necessary to address reliability
and economic impact issues.
www.powermag.com
65
MERCURY REMOVAL
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properties. Meets Class 2 RMA and ASTM requirements.
800-537-4483
MERCURY REMOVAL
1. Relationship between SO2 conversion and Hg0 oxidation across activity for a conventional catalyst. Source: Hitachi Power Systems America Ltd.
2.0
1.5
0.0
0.0
0.5
1.0
1.5
2.0
New
Release!
Find cogen power plants in India, list new coal-ired projects in Europe,
track hydroelectric projects in Brazil, and more ...
The Platts UDI World Electric Power Plants Database (WEPP) is an inventory of over 160,000
generating units including more than 70,000 plants of all sizes and technologies in more
than 225 countries. Operators include regulated utilities, private power companies, and
commercial and industrial autoproducers (captive power).
This unique database is the largest global power plant information resource available and has
been published in its current format since 1990.
For more in
formation
about Platt
s UDI
databases
and
directories,
visit
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ata.com.
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North America
+1-800-PLATTS8 (toll-free)
+1-212-904-3070 (direct)
68
EMEA
+44-(0)20-7176-6111
www.powermag.com
Latin America
+54-11-4804-1890
Asia-Paciic
+65-6530-6430
MERCURY REMOVAL
70
TRAC
100
90
Hg oxidation (%)
80
70
60
50
644
680
716
752
788
Temperature (F)
3. Schematic of SSR test configuration. Source: Hitachi Power Systems America Ltd.
WFGD
Boiler
DESP
De-NOx
AH
Stack
fan
SSR pilot
TF
1st layer
SCR
reactor
(actual)
DP
SSR
2nd layer
3rd layer
ID
Control
valve
4th layer
TF
Table 1. Coal and flue gas analysis during slipstream reactor testing.
Source: Hitachi Power Systems America Ltd.
Coal analysis
8,280
Moisture (% as received)
30%
O2 (% dry)
Ash (% as received)
5.2%
CO2 (% dry)
Sulfur (% as received)
0.3%
H2O (%)
12.6
HCl (ppm)
14
Chlorine (ppm)
33
Hg (ppm)
0.1
www.powermag.com
260300
2.9
15
MERCURY REMOVAL
4. Slipstream reactor mercury speciation measurements. Source: Hitachi
Power Systems America Ltd.
Concentration (ppm)
Concentration (ppm)
Particle Hg
50
50
Oxidized Hg
Elemental Hg
Initial (January, 2006)
40
30
20
10
0
40
30
20
10
0
Concentration (ppm)
Concentration (ppm)
Concentration (ppm)
50
40
30
20
10
0
50
40
30
20
10
0
50
40
30
20
10
0
Inlet
Middle
Sampling point
Outlet
80
60
NOx (ppm)
20
2,000
4,000
6,000
8,000
50,500
626752 (698)
180230
Chlorine (ppm)
110350 (130)
Bromine (ppm)
050 (0)
90
Operating hours
October 2011 POWER
10,000
Condition
www.powermag.com
71
MERCURY REMOVAL
6. Schematic of the pilot test facility at Southern Companys Mercury
Research Center. Source: Hitachi Power Systems America Ltd.
7. The arrangement of the two layers of catalyst installed during pilot testing at Southern Companys
Mercury Research Center. The catalyst volume was 6.7 m3. Source: Hitachi Power Systems America Ltd.
AH
Boiler
SCR
AH
EP
FF
Fan
14m
8. Mercury oxidation activity of the catalyst versus halogen concentration. Source: Hitachi Power Systems America Ltd.
1.2
TRAC
1.0
Conventional
0.8
0.6
0.4
Temp. 370 C
Br:0 ppm
0.2
0.0
0
100
200
300
400
CI (ppm)
9. Mercury oxidation activity of the catalyst versus flue gas temperature. Source: Hitachi Power Systems America Ltd.
1.4
1.2
TRAC
1.0
Conventional
0.8
0.6
0.4
0.2
0.0
320
Br:5 ppm
CI: 125-150 ppm
340
360
380
400
Temperature (C)
72
www.powermag.com
420
MERCURY REMOVAL
Table 3. Coal and flue gas analysis for first commercial application of
TRAC. Source: Source: Hitachi Power Systems America Ltd.
Coal analysis
Heating value (Btu/lb as received)
Moisture (% as received)
28.731.0
Ash (% as received)
4.95.7
723741
Moisture (%)
11.013.8
O2 (% dry)
2.93.1
16.016.6
17.933.6
CO2 (% dry)
Sulfur (% as received)
0.270.36
NOx (ppm)
297336
Chlorine (ppm)
2554
HCl (ppm)
0.420.57
Fluorine (ppm)
3361
HBr (ppm)
0.010.13
0.1
Cl2 (ppm)
0.040.07
Hg (ppm)
10. Effect of TRAC catalyst on Hg oxidation and removal across the wet
flue gas desulfurization system before and after TRAC replacement.
Source: Hitachi Power Systems America Ltd.
Hg(0)
Wet FGD inlet
Hg (g/dscm)
10
8
6
4
2
0
April 2008
June 2008
80
Hg removal (%)
Hg (g/dscm)
Hg (g/dscm)
Hg(2+)
60
40
20
0
April 2008
Existing 3 layers
without TRAC
10
8
6
4
2
0
April 2008
June 2008
80
60
40
20
0
June 2008
Existing 2
layers with one
layer of TRAC
April 2008
Existing 3 layers
without TRAC
June 2008
Existing 2
layers with one
layer of TRAC
700
700
600
600
500
500
Power (MW)
Power (MW)
11. Mercury CEM system data collected before (left column) and after (right) one layer of TRAC replaced a
conventional layer of catalyst. Source: Hitachi Power Systems America Ltd.
400
300
200
100
300
200
100
0
4/22
4/27
5/2
0
5/26
5/7
100
100
80
80
Hg(2+)/Hg(T) (%)
Hg(2+)/Hg(T) (%)
400
60
40
20
0
4/22
4/27
5/2
5/7
5/31
6/5
6/10
6/15
6/20
6/25
6/30
5/31
6/5
6/10
6/15
6/20
6/25
6/30
60
40
20
0
5/26
www.powermag.com
73
MERCURY REMOVAL
Table 4. Economics of TRAC catalyst for a typical 680-MW unit. Source: Hitachi
Power Systems America Ltd.
3 regular
layers
1 TRAC plus 2
regular layers
3 TRAC layers
90
92
95
10
7,600,000
4,600,000
30
63
80
1.5
1.0
0.5
1,140,000
760,000
380,000
Coal type
Eastern bituminous
Notes: Assumes $0.75/lb for untreated activated carbon. MACF = million actual cubic feet.
activity of the TRAC catalyst was significantly higher than that of the conventional
catalyst with low-chlorine coal. Figure 11
presents the Hg CEM results before and after
TRAC replacement.
The superior performance benefits of
TRAC have been demonstrated, but what
about the costs? The economics of adding
TRAC catalyst are illustrated in Table 4. For
most eastern bituminous coal applications,
the existing catalyst is sufficient to oxidize
the mercury. However, some units can benefit from an extra boost of mercury oxidation
with one or two layers of TRAC. For PRB
applications, TRAC can help to minimize the
amount of ACI required and thereby save the
cost of mercury oxidation.
The most cost-effective mercury control
strategy is to use existing equipment in order
to comply with new standards. In particular,
Southern Company has evaluated mercury
oxidation across catalysts with enhanced
mercury oxidation, such as TRAC. This strategy requires that the oxidation be maintained
across a range of temperatures, fuel halogen contents, and NOx control levels. Such
a catalyst would allow utilities to reduce or
eliminate the need for halogen injection and
simultaneously comply with stringent NOx
emission standards.
Based on pilot-test results, Southern
Company moved forward with full-scale
applications of TRAC catalyst at several
generating facilities burning PRB and bituminous fuels.
74
www.powermag.com
PLANT DESIGN
1. More information made available. This example illustrates how it is now possible
to dynamically view risk profiles across an industrial complex using color. Source: INOVx
Probability of failure
Consequences of failure
0
13
28
30
64
61
49
49
149
74
382
63
53
51
181
115
PLANT DESIGN
field conditions can be explored, accurate
measurements taken, and general productivity dramatically improved. Consider the
desire to limit the exposure of workers to
radiation at nuclear plants as a means of immediately monetizing the value of converting
field work to office work.
Figure 2 shows two accurate laser images
of a plant. These are full 3-D images with every pixel accurately known in 3-D space to
better than 5 mm. Though the images can be
rotated, panned, and zoomed to any perspective, the included images represent a small
sample of what is possible.
3-D Virtual Models for Outages. Plant
outages are complex endeavors with myriad
distinct work packages involving significant
internal staff, and often hundreds (and sometimes thousands) of contractors and suppliers.
3-D virtual models of the affected facilities enhance communications and ensure team familiarity with tasks and their environment without
time-consuming walkthroughs of the facility.
2. Believe it or not. Yes, these are laser scans, not photos. Courtesy: INOVx
76
www.powermag.com
circuits were documented using 2-D isometric drawings with manual placement
of the thickness or corrosion monitoring
locations (TML/CML). In parallel, a database was kept showing corrosion rate, date
of last inspection, and other data for each
point. The challenges in coordinating and
maintaining accuracy under this system
should be obvious.
Today, inspection circuits are generated in
3-D as a subset of the overall virtual model.
TML/CML points are called out in their exact
geospatial location and linked dynamically to
the source data. Even more important, these
inspection points are determined by using
the 3-D virtual model, permitting risk-based
techniques to be used that reduce the number
of inspection points by over 50% without increasing plant operating risk. This has a double benefit of reducing the total hours spent
inspecting the plant by 20% to 30% while increasing its reliability and safety (Figure 3).
Inspectors use the 3-D virtual model to
determine scaffolding needs as well as access limitations and safety requirements.
As one inspector from Shell Oil put it,
One hour using the virtual model saves
me 8 hours in the field.
PLANT DESIGN
3-D Virtual Models in Plant Operations. There are many opportunities to uti-
How It Works
The path to AV is surprisingly easy. The
steps are:
1. Identify the specific uses that will be
improved with AV, and plan the implementation.
2. Create the 3-D virtual model of the plant
facilities.
3. Add intelligence to the model by naming
all the components and connecting them to
the existing enterprise information stores.
4. Establish the new work flow and processes.
5. Assess the implementation and explore
new potential uses.
Start by reviewing the area of potential
benefits, understanding the priorities and
value, and planning the implementation. This
involves reviewing current work practices,
as well as suspected areas of improvement.
Plant personnel are intimately involved in
this step.
Next, the as-built 3-D virtual model of
plant facilities and assets is created. If a 3-D
design model is available, it is used, but only
as the starting point. If one does not exist, then
conventional laser scanning technology (widely available from many vendors) is used.
Modeling software is employed to convert
the laser scan point cloud into 3-D objects.
The end result is a visual, navigable, multiperspective 3-D model that accurately and
precisely reflects the actual facilities. The
3-D virtual model software must be capable
of accepting updates at any time from new
oal-fired power plants produce approximately 40% of the electricity generated in Maryland. Constellation Power
Source Generation Inc. (CPSGI), an affiliate
of Baltimore-based Constellation Energy,
owns and operates three of these plants that
help meet the growing demand for electricity.
Although more than half of the coal combustion by-products (CCBs) produced by these
three plants is recycled for reuse in products
such as cement and concrete, not all can be
reused due to a lack of market demand. The
remainder is placed in landfills permitted to
dispose of such materials.
78
Permitting Process
While CPSGI and Charah were evaluating
alternative disposal locations for CPSGIs
CCBs, the MDE began reforming its regulatory program and issued a 68-page report
detailing proposed action on regulations associated with CCBs. The purpose of this action was to establish requirements pertaining
to the generation, storage, handling, processing, disposal, recycling, beneficial use, or
other uses of CCBs.
Name:
Dan Wagoner, Superintendent
Engineering & Maintenance,
Dominion Terminal Associates
On Partnering With Us:
I dont think you can do any better than Flexco.
Dave Wood - Flexco - North American Sales Manager; Dan Wagoner - Dominion Terminal Associates - Superintendent Engineering & Maintenance;
Steve Kaluzny - Flexco - Project Manager; Wesley Simon-Parsons - Dominion Terminal Associates - Civil & Environmental Supervisor
Dominion Terminal Associates, the second-largest coal exporter in the U.S., was
experiencing problems with spillage at its transfer points. As Dan put it, We looked
into it and we saw we were losing a lot of time and money with cleanup and lost coal.
He decided to talk to Flexco.
Our team designed and installed transfer chutes that worked within Dominions existing
stacker-reclaimer units. The new systems not only cut down on spillage and delivered
soft, centered loads to the belts they also reduced dust, plugging and wear. Today,
reclaimed tonnages are up and transfer issues are down.
We feel comfortable moving more tons per hour now, Dan says. Two million tons
have gone through the Flexco system, and its worked very well. To increase the
performance of your system, call 1-800-541-8028 or visit our website today.
FLEXCO.COM
1. The final act. Layout of a typical landfill used for the disposal of coal combustion
by-products (CCB). Courtesy: Constellation
Power Source Generation Inc. (CPSGI)
Final cover
system
Leachate
collection
system
2. Topping it off. Upon reaching fill capacity, the cells of the CCB landfill will be closed by
placing a 24-inch clay cover layer on top of the CCBs and a 40-mil HDPE liner system over top
of the cover layer. Courtesy: CPSGI
Geocomposite drainage layer
Vegetation
6 topsoil
Geomembrane
12 protective layer
12 drainage layer
Liner
system
80
24 compacted clay
(k=1x10-7 cm/sec)
Patapsc
o aquife
r
Geomembrane
690
4. Installing the liner. Crews complete the installation of a 60-mil textured HDPE liner
at the site of the future CCB landfill in Maryland. Upon installation, welds are tested for their
conformance with the technical specifications by third-party testing. The test must be submitted for approval to third-party construction quality assurance personnel and the MDE. Courtesy:
Photography by David Starling of CPSGI
5. Successful teamwork. Charah President and CEO Charles Price (left) and CPSGI President John Long discuss the 60-mil textured HDPE liner used at the CCB landfill called Lot 15.
Courtesy: Photography by David Starling of CPSGI
82
www.powermag.com
and other landfill areas as needed, via water truck (Figure 6).
To secure the active area and avoid dusting after hours, Charah will apply hydromulch on a daily basis across the exposed
CCB surface. Hydro-mulch is a hydrated
straw mulch that contains tacking agents
that allow the material to adhere to the
CCBs. The hydro-mulch will provide an
initial barrier that will mitigate any possible wind or stormwater runoff erosion.
NAES
www.naes.com
www.powermag.com
83
NEW PRODUCTS
NERC CIP
Information
and Security
E-Learning
Series
Global Training Solutions
Inc. released an
interactive, self-paced,
and fully customizable
electronic training
program to achieve
compliance with
the North American
Electric Reliability
Corp.s (NERCs) Critical
Infrastructure Protection (CIP) security standards. The
company designed its NERC CIP Information Security
E-Learning Series on open-web standards, sharable
content object reference model (SCORM) compliance,
and advanced technical concepts. It says that through
its program, system operators can earn a fraction
of their continuing education credit hours for NERC
requirements.
Courses incorporate text, voice, video, animation,
simulation, interactive sessions, testing, and
reporting. The e-learning series is part of a complete
awareness and training program that promotes and
reinforces critical security principles, the company
says. The program also incorporates a variety of other
security awareness aids such as posters, calendars,
brochures, newsletters and e-mail tips. (www.
globaltrainingsolutions.ca)
84
www.powermag.com
NEW PRODUCTS
Preventing Dust
Accumulation on Beams
BeamCaps signature product, the BeamCap,
prevents dust accumulation on I-beams,
structural steel members, pipes, cable trays, and
other difficult-to-clean areas. BeamCap pieces
completely enclose the structures, eliminating
horizontal surfaces where dust consistently
builds up. This eliminates the need for cleaning
in hard-to-reach places and greatly reduces the
potential for fires and secondary explosions.
The aluminum enclosures also resist and protect
against corrosive elements. The patent-pending
BeamCap is attached by using industrialstrength magnets so that installation does not
require a welder, a hot-work permit, or even
a drill. In addition to simple installation, the
use of magnets makes it easy to comply with
the OSHA requirement that covered surfaces be
periodically inspected. (www.beam-cap.com)
www.powermag.com
85
ANNUAL MEETING
HONG KONG
CO-HOSTS
GRAND SPONSOR
ORGANIZERS
DIAMOND SPONSOR
PLATINUM SPONSORS
GOLD SPONSORS
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Direct Mail
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800.290.5460 I POWER@theYGSgroup.com
The YGS Group is the authorized provider of custom reprint products from POWER.
FOR SALE/RENT
24 / 7 EMERGENCY SERVICE
BOILERS
847-541-5600
FAX: 847-541-1279
WEB SITE: www.wabashpower.com
P.O. Box 60
Columbia, TN 38402 USA
ph: 931/388-0626 fax: 931/380-0319
www.pugmillsystems.com
wabash
READER SERVICE NUMBER 208
POWER
EQUIPMENT CO.
DIANE HAMMES
Phone: 713-444-9939
Fax: 512-213-4855
dianeh@powermag.com
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ABB Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . 17
www.abb.com/powergeneration
Albemarle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 . . . . . . . . . . . . 37
www.albemarle.com
Alcatel-Lucent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . 3
www.alcatel-lucent.com/smartgrid
Ambitech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 . . . . . . . . . . . . 36
www.ambitech.com
AREVA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 . . . . . . . . . . . . 39
www.areva.com
Babcock & Wilcox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4 . . . . . . . . . . . . 42
www.babcock.com
Babcock Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 . . . . . . . . . . . . 25
www.babcockpower.com
Beumer Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . . . . . . 6
www.beumer.com
Carboline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . 14
www.carboline.com
CMP Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . 13
www.cmp.co.jp/en
ConocoPhillips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . . . . . . . . . . 24
www.conocophillips.com
Diamond Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 . . . . . . . . . . . . 27
www.diamondpower.com
Emerson Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . . . . . . . . . 22
www.emersonprocess.com
Fenner Dunlop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 . . . . . . . . . . . . 38
www.fennerdunlopamericas.com
Flexco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 . . . . . . . . . . . . 40
www.flexco.com
Fuel Tech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . 7
www.ftek.com
General Physics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . . . . . 5
www.etaproefficiency.com
HACH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 . . . . . . . . . . . . 28
www.hach.com
Hadek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . 11
www.hadek.com
Harrington Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . 8
www.harringtonhoists.com
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www.powermag.com
COMMENTARY
Shaping Americas
Energy Policy
By Richard F. Dick Storm
mericas energy and environmental policies have been dysfunctional for decades. Obsessively moving toward green
has made America weaker and has damaged our economy. During POWERs first 100 years (18821982), the magazine
chronicled the U.S. growing into the strongest industrialized
economy in the world. America designed and built products for
the world using raw materials and energy from within our own
borders. Now we are in a recession and the U.S. Environmental
Protection Agencys (EPA) War on Coal continues. Does anyone
get the connection? Ever-worsening regulations are killing jobs
by the thousands.
www.powermag.com
DISCOVER SOLUTIONS
MAY 15-17,
2012
14 TH ANNUAL
BALTIMORE, MD
BALTIMORE CONVENTION CENTER
Its that easy. First, add The Babcock & Wilcox Company (B&W) to your contact list. Then,
call us. We provide complete air quality control system upgrades, services and replacement
parts for the life of your equipment, regardless of the original manufacturer. Benefit from
improved removal efficiencies, increased reliability and simplified maintenance processes.
Eliminate the challenges of multiple suppliers and specialists. Contact us today to arrange a
consultation with a B&W environmental field specialist.
1-800-BABCOCK (222-2625)
www.babcock.com/pggcapabilities3