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CONFIDENTIAL 1
Contents:
Sr. No Description Slide
5.0 Conclusion
Isgec & Fuel Tech Overview
CONFIDENTIAL 3
BRIEF OVERVIEW: ISGEC
Well diversified product portfolio that includes Power Plants, Boilers, Sugar
& Machinery, Process Plant Equipment, Presses and Iron & Steel Castings .
Global foot prints across the world with presence in more than 78 countries
in various sectors like Sugar, Chemical, Textile , IPP, Oil and Gas Sector &
Cement etc.
Entered into licensing agreement with Foster Wheeler USA in 2010 for
supplying large Pulverized Coal fired boilers for utility segment in Subcritical
and Supercritical pressure range upto 1000 MW .
CONFIDENTIAL 4
BRIEF OVERVIEW: ISGEC
EPC Power Process Equipment
Boilers
Plants
Sugar Plants & Steel Castings
Presses
Machinery
CONFIDENTIAL 7
Recent NOx Regulations in India:
As per Union Govt. MoEF Notification December 7, 2015 the NOx regulations are;
Note: Reference O2 ‐ 6% Dry Vol. basis
CONFIDENTIAL
Selective Non-Catalytic Reduction
(SNCR) Technology
CONFIDENTIAL 9
NOxOUT® SELECTIVE NON-CATALYTIC
REDUCTION (SNCR)
• In-furnace, Post-combustion NOx
Control
• Injection of Diluted Urea Reagent in
Upper Furnace:
– Low Energy, High Momentum
Droplets
– Controlled Distribution through
specifically designed Injectors
– In-furnace, Gas Phase Reactions
between NH3 & NOx
• Process Reaction Temperature Range:
1600°F to 2200°F
• Reductions Ranging from 10 to 70
Percent, Limited by Application, Fuel, and Allowable
NH3 Slip
CONFIDENTIAL 10
SELECTIVE NON-CATALYTIC REDUCTION
(SNCR) – UREA BASED
SNCR Process Chemical Reactions
4NO + 2CO(NH2)2 + O2 4N2 + 4H2O + 2CO2
2NO2 + 2CO(NH2)2 + O2 3N2 + 4H2O + 2CO2
Nitrogen Oxides + Urea + Oxygen Nitrogen + Water Vapor + Carbon Dioxide
CONFIDENTIAL 11
SNCR – WHY UREA
Urea droplets formed by FTI injectors are characterized in test facilities using laser Doppler techniques.
CONFIDENTIAL 12
Ammonia Risks
Anhydrous Ammonia
Aqueous Ammonia Not Much Better
LARGE UNIT UTILITY CONSIDERATIONS
CONFIDENTIAL 14
CONFIRMING SNCR NOx REDUCTION
PERFORMANCE
• Gathering of Data and Information
o Operational Data
o Drawings
• Temperature and Species Mapping
o Upper Furnace Temperatures, NOx, CO, and O2
• Computational Fluid Dynamics (CFD), Chemical Kinetics
Modeling (CKM), and Injector Modeling
o Boiler Model for Performance and Injector Placement
o Tools Combined with Experience and Know-how
• Demonstration System Option
o 2 to 3 Week Test System
o Fuel Tech Personnel for Setup, Operation, and Teardown
CONFIDENTIAL 15
UPPER FURNACE MEASUREMENT GOALS
CONFIDENTIAL 16
SNCR INJECTION STRATEGIES
• NOxOUT® Technology
o Air Atomized Urea Injection
o Larger Droplet Size for Hot and/or Large Boilers and Furnaces
• High Energy Reagent Technology (HERT)
o Mechanically Atomized Urea Injection via Injectors in Upper Furnace
o Recent Applications with Low Baseline Applications and Control Levels at
or Below 0.100 lb/MMBtu
• Multiple Nozzle Lances (MNLs)
o Air Atomized, Fine Mist
o Convection Pass Injection
• Combined Injection Strategy for Significant NOx Reduction with
NH3 Low Slip Control
CONFIDENTIAL 17
SNCR SYSTEM LAYOUT
FURNACE
NOTES
1) Permanent Tanks – 40,000 Gallon Capacity, Double‐ Multiple Nozzle Lance
wall Construction Continuous Emissions MNL Distribution (3 on each side of furnace)
Module
Monitoring System (CEMS) Zone 3
2) IZM shown out of position ‐ normally installed at one
Wall Injectors and
of the injection elevations. Distribution Module
Zone 2
Signals to/from Wall Injectors
Zone 1
Plant DCS
Master Control
Module Control Room
(Optional)
Mixed Chemical Piping
to Level 1 Injectors
Electric Power
Concentrated Urea
NOxOUT "A" Reagent Circulation Loop
FRP Storage Tank
(See Note 1)
Mixed Chemical Piping
to Level 2 Injectors
Electric Power
Electric Power
Mixed Chemical Piping
to Level 3 (MNLs)
WATER IN
Injection Zone Metering
Module (IZM‐3) Note 2
High Flow Delivery (HFD)
Spill Protection and Circulation Module
(Enclosure Optional)
Dilution Water Pressure (DWP)
Control Module
CONFIDENTIAL 18
TYPICAL SNCR EQUIPMENT
CONFIDENTIAL 19
BALANCE OF PLANT ISSUES
CONFIDENTIAL 20
UREA STORAGE SYSTEM
Dry Urea Silo
Reagent
Storage Tanks
CONFIDENTIAL 21
SOLUTIONIZING EQUIPMENT
CONFIDENTIAL 22
CIRCULATION MODULE
CONFIDENTIAL 23
METERING MODULE
CONFIDENTIAL 24
DISTRIBUTION MODULE AND BUILDING
CONFIDENTIAL 25
WALL INJECTORS
CONFIDENTIAL 26
HERT BLOWER SKID
Motorized
Butterfly
Valves
MBV
Discharge
Piping
Redundant
Blowers
Suction
Piping
CONFIDENTIAL
HERT INJECTORS
Blower Air
Isolation
Valve
CONFIDENTIAL
NOXOUT® INJECTION
CONFIDENTIAL
SNCR INJECTOR WITH RETRACT
CONFIDENTIAL
MULTIPLE NOZZLE LANCE (MNL)
CONFIDENTIAL
MNL IN THE BOILER
CONFIDENTIAL
MNL TESTING
CONFIDENTIAL
FUEL TECH EXPERIENCE AND BENEFITS
CONFIDENTIAL
ASCR/SCR Technology
CONFIDENTIAL 35
SCR SYSTEM REAGENT OPTIONS
Flammability
Anhydrous Ammonia
Health Reactivity
‒ Least Expensive (Coming in the Gate)
‒ Extremely Hazardous Chemical, Highest Risk Protection
Ammonia {NH3}
36 CONFIDENTIAL
ON-SITE UREA CONVERSION OPTIONS
37 CONFIDENTIAL
THERMAL DECOMPOSITION – HEAT SOURCE
Energy for
Carrier Medium: Decomposition
Ambient Air, Clean Reactions Provided by
Flue Gas NG Burner, Electric
Heater, or Preheated
Flue Gas
Injection of Aqueous
Reagent Delivered to the
Urea in Temperature Urea Injector
+ Time Ammonia Injection Grid
and Time Dependent + Temp (AIG) at the Required
Chamber – Very = NH3 +
Pressure and Temperature
Responsive to HNCO To AIG
Based on SCR Demand
Changes in NH3
Signal
Demand
38 CONFIDENTIAL
ASCR DESIGN PRINCIPLES
• Selective Catalytic Reduction (SCR) is
limited in application due to high capital Lower NOx Baseline
cost requirements and retrofit difficulty. via Combustion and
SNCR Improvements
• The ASCR approach can achieve similar
overall NOx reduction as an SCR but
with a greatly reduced capital cost. Less Catalyst
L
SCR REACTORS
CONFIDENTIAL 42
TYPICAL APPROACHES TO SOLVING ASH
BUILD UP ISSUES
CONFIDENTIAL 43
COMPARISON PLATE - HONEYCOMB
CATALYST
pitch
pitch
Plate Type Structure Honeycomb Structure
• Flexible Plates With Notches to Maintain Pitch • Rigid Structure
• Large Rectangular Openings • Square Openings/Increased Surface Area
• High Void Fraction (>85%) •Void Fraction >75%
• Pitch: ~5 to 7 mm • Pitch: 7 to 10 mm (for coal‐fired applications)
Universal Sized Frames for
Plate and Honeycomb
(~3.2’ by 6.2’)
Coal High Dust SCR Catalyst Selection
Site Specifics Dictate Catalyst Selection
NOx Removal, SO2:3 Conversion, Temperature, Required
Reactor Potential, Dust Loading
Honeycomb Catalysts
Moderate to High Dust Loading Levels Existing in
Predominance of Boiler Power Plants, Waste
Incinerators, and Other Industrial Applications
Gas Turbine and Engine Applications
Higher Surface Area per Unit Volume (+20 to 30% for
High Dust)
Plate Catalysts
Preferred for Extreme High Dust Application in Coal Fired
Boilers (>20 gr/dscf or 40,000 mg/Nm3)
When Specified Honeycomb Catalyst Pitch is Unusually
High Considering Application Requirements
When Replacement of Existing Plate Catalyst is Preferred
by a Client
Higher DeNOx Activity Offsets Reduced Surface Area
Lower Production Cost/m3 and Faster to Produce
SONIC HORNS FOR SCR APPLICATIONS
CONFIDENTIAL 46
Ash Sweepers & Acoustic Cleaners
A Non-Erosive On-Line Catalyst Cleaning System
CONFIDENTIAL 47
GRADUATED STRAIGHTENING GRID (GSG™)
FLUID DYNAMICS - PATENTED
48
GRADUATED STRAIGHTENING GRID GSG
• The even and parallel flow into the catalyst ensures no plugging and
high performance
• The GSG is the prime flow gas turning device to achieve this
• A conventional reactor was replaced with a GSG in 2012 (800 MW)
CONFIDENTIAL
BASELINE RESULTS - VELOCITY
High and low spots from the turning vanes are helped by the straightening grid and
perforated plate but still yield a poor distribution into the 1st catalyst layer.
Vectors near vanes show recirculation areas where potential
ash fallout can occur.
FINAL RESULTS - VELOCITY
ASCR/SCR Technology
Flow shadows from large truss reduced with new design.
Flow vectors all down, no recirculation
Conclusion
CONFIDENTIAL 52
Advanced Modeling Services
TYPICAL POWER PLANT – All Technologies
Conditioning Systems
CONFIDENTIAL 53