NOx Control in Thermal Power Plants

CONFIDENTIAL 1
Contents:
Sr. No Description Slide

1.0 Brief Overview of Isgec & Fuel Tech

2.0 Recent NOx Regulations in India

3.0 SNCR Technology

4.0 ASCR / SCR Technology

5.0 Conclusion
Isgec & Fuel Tech Overview

CONFIDENTIAL 3
BRIEF OVERVIEW: ISGEC

 A Multi Product Heavy Engineering Public Limited Company established in

the year 1933.

 Well diversified product portfolio that includes Power Plants, Boilers, Sugar
& Machinery, Process Plant Equipment, Presses and Iron & Steel Castings .

 Positive Net worth and Zero debt company.

 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

Contract  Liquefied  Gas   APCE

Manufacturing Containers
CONFIDENTIAL 5
 FUEL TECH OVERVIEW

• FUEL CHEM® Technology

‒ Boiler Efficiency and Availability Improvements
‒ Slag and Corrosion Reduction
‒ Controls SO3 Emissions and Addresses Related Issues
• Innovative Approaches to Enable Clean Efficient Energy
‒ NOX Reduction Technologies include Combustion Modifications, SNCR,
ASCR, RRI, ULTRA
‒ Field Optimization Services
• Flow Modeling and SCR Catalyst Management Services
‒ Computational Flow Dynamics and Physical Flow Modeling for Power
Plant Systems
‒ SCR System Optimization and Catalyst Management Services
• Technology solutions based on Advanced Engineering Computer
Visualization and Modeling
• Strong Balance Sheet (Stock Symbol: NASDAQ – FTEK)
CONFIDENTIAL 6
Recent NOx regulations in India

CONFIDENTIAL 7
Recent NOx Regulations in India:

 As per Union Govt. MoEF  Notification December 7, 2015 the NOx regulations are; 

Pollutant Unit TPPs  TPPs installed  TPPs to  be 

installed  after 2003 to  installed 
before  December 31,  from 
December  2016 January 1, 
31, 2003 2017 

NOx mg /Nm3 600 300 100

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

• NOx Removal Efficiency is Related to Normalized

Stoichiometric Ratio (NSR)
Actual Mole Ratio of Urea to Baseline NOx
NSR =
Theoretical Mole Ratio to Reduce One Mole of NOx

o The Measure of the Rate at Which Urea is Added to the

Flue Gas Relative to the Amount of Baseline NOx

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

• Utility Unit NOx Reductions ranging from 10 – 30%

• LNB and OFA Operation
o Potential for High CO and Temperature
o Lower NOx Baselines
• Large Furnaces with Internal Platens
• Some Large Units are Relegated to Load Following
o Larger Load Ranges for NOx Reduction
• Better Understanding of Combustion and Upper Furnace
Conditions
• High NOx Reduction and Smaller Gas Volume
o Do not treat 100% of the Flue Gas

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

• High Velocity Thermocouple and

Probe to Extract Flue Gas
• Measurement of Upper Furnace
Temperatures and Species
o Concentrations of O2, CO, and
NOx
• Data taken typically at three (3)
loads; full, mid, and low load
• Testing on front and side walls to
obtain realistic view of temperature
and species differences at each
plane.

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

• Reagent Storage and Circulation

o Circulation Module to be located in-doors and has pump
redundancy
o Tanks sized for ten (10) days storage at full load
• Metering and Distribution
o Control valve based metering modules for quick response
• Injectors
o Investigating Wall Injectors Only
• DCS Control System
• Option for Dry Urea Storage and Solutionizing
o Dry storage should be four (4) days storage at full load
o Equipment to be located indoors

CONFIDENTIAL 19
 BALANCE OF PLANT ISSUES

• Atomizing Air – Compressed Air

• Water
o Dilution Water for Injection
o Solutionizing Water Option
• Power
o 415 VAC
• DCS Controls

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

• NOxOUT Injectors • HERT Injectors

CONFIDENTIAL 26
 HERT BLOWER SKID

Motorized
Butterfly
Valves
MBV

Discharge
Piping

Redundant
Blowers
Suction
Piping

CONFIDENTIAL
 HERT INJECTORS

Blower Air
Isolation
Valve

Dilution Water &

UREA Isolation
Valve
Injector

CONFIDENTIAL
NOXOUT® INJECTION

CONFIDENTIAL
 SNCR INJECTOR WITH RETRACT

Retract & Injector

Assembled Retract & Injector Installed

CONFIDENTIAL
MULTIPLE NOZZLE LANCE (MNL)

CONFIDENTIAL
MNL IN THE BOILER

CONFIDENTIAL
MNL TESTING

CONFIDENTIAL
 FUEL TECH EXPERIENCE AND BENEFITS

• Extensive Commercial Experience

o Over 100 LNB/OFA Systems from 20 MW to 1200 MW
o Over 650 NOxOUT and HERT Systems Worldwide, More Than
100 Utility Applications
o Over 55,000 MW of SCR Design, 20,000 MW AIG Tuning
Experience Worldwide
o NOxOUT ULTRA® Systems, Over 100 Units to Date, 5 to
1,250 PPH of SCR Reagent Feed Systems
• Fuels and Boiler Types
o Coal, Biomass (Wood, MSW, Bagasse, Etc.), Gas, Oil, Tires,
Etc.
o T-Fired, Stoker, Wall Fired, Down Fired, Incinerators, CFB,
BFB, Etc.
• Quality Equipment with Low Maintenance Cost
o Stainless Steel Design for Long Life and Durability
• Guaranteed Performance
o NOx Reduction, NH3 Slip, Reagent Consumption, Power
Consumption, CO, LOI

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}

‒ Requires RMP, Extensive Safety Training, Evacuation Plan

 Aqueous Ammonia
‒ 29% Concentration – Limited Availability, No OSHA Relief
‒ 19% Concentration – More Widely Available, No RMP
 On-Site Conversion of Urea
Flammability
‒ Significant Safety Advantages
Health Reactivity
‒ Large Installed Base
Urea {CO(NH2)2}
‒ No Impact on Catalyst Life or SCR Performance Protection

‒ Urea is a Worldwide Commodity

36 CONFIDENTIAL
 ON-SITE UREA CONVERSION OPTIONS

ULTRA™ Thermal Decomposition • Energy Required for

Process Decomposition
Typically Provided by
Natural Gas, Oil-fired
Burner, Electric Heater,
or GT Exhaust
• Urea Flow Adjusted by
NH3 Demand Signal
Sent to the Metering
Pumps
• Urea Can Be Sourced
in Solid Form – Prill or
Granular – and then
Solutionized On-site
• Fast Response,
Excellent Turndown

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

• An ASCR combines multiple low capital

cost technologies including Low-NOx Minimal Duct Modifications
burners, OFA, and/or SNCR in
combination with a compact SCR
reactor.
• The ASCR reactor requires less catalyst,
a smaller footprint and less duct Substantially Less 
Capital Cost 
modifications - all resulting in a greatly
reduced capital cost when compared
with a traditional SCR.
 ADDITIONAL ADVANTAGES OF ASCR
TECHNOLOGY

• Better Reagent Utilization

o SNCR Process
o Separate AIG
• Low Pressure Drop
• Low SO2 to SO3 Conversion Rate
• Broader Range of Operation
o Lower Electrical Demand
o SNCR may Perform at Low Loads, with Essentially No NH3 Slip
to Catalyst
• Hg Oxidation Across the Catalyst
 STATIC MIXERS

• Fuel Tech custom designs, engineers

and builds static mixers

L
SCR REACTORS

CONFIDENTIAL 42
 TYPICAL APPROACHES TO SOLVING ASH
BUILD UP ISSUES

• Catalyst Change Out

Larger Pitch
Honeycomb/Corrugated to Plate Type Catalyst
• Flow Model Studies
Physical & CFD
• Modifying Turning Vanes & Distribution Devices
• Installing/Adjusting LPA Screens

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

• Dramatically Improves Flue Gas Velocity Distribution without Increasing Cost,

Complexity or Compromise on Performance
• Minimizes Angle at which Ash Particles Enter Catalyst, Near Perfectly Vertical Flow
into Catalyst
• Innovative Design Allows for
o Higher Flue Gas Velocity, Improved Operating and Financial Performance via Longer Catalyst Life and
Reduce Downtime
o Reduction in Time Required to Tune Ammonia Injection Grid
o Higher Flue Gas Velocity Translates into Smaller Cross-section and Less Pressure Drop, Lower Capital

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

Post Combustion Technologies

SCR Design and Catalyst

Combustion
Management Services
Technologies

Fuel Tech Technologies Non‐Fuel Tech Supplied

• ASCR™ Advanced SCR: System which combines LNB + OFA +  • SCR Services: Selective Catalytic Reduction Services  • Baghouse: Controls Particulate 
SNCR + AIG + GSG™ + Catalyst which include: optimizing process design, catalyst  Matter (PM) from flue gas
• AIG: Ammonia Injection Grid selection, and improving the overall performance  • ESP: Electrostatic Precipitator for 
• GSG™: Graduated Straightening Grid of SCR PM Control 
• HERT™: SNCR system using high energy injectors • Static Mixer: Equipment used to mix temperature,  • Wet FGD: Scrubber to maximize 
• LNB: Low NOx Burners velocity, and NOx to optimize SCR performance  SO2 removal using Flue Gas 
• NOxOUT®: SNCR system using high momentum injectors ahead of the AIG De‐Sulfurization (FGD)
• ULTRA™: Urea‐based ammonia generation system for SCR • TIFI® Targeted In‐Furnace Injection™: Chemical  • Dry FGD: Scrubber to remove 
• SCR: Selective Catalytic Reduction Injection Programs used to target slag control SO3 SO2 with less water than Wet 
• SNCR: Selective Non‐Catalytic Reduction mitigation, and fuel flexibility ESP Rebuild and Flue Gas
FGD

Conditioning Systems
CONFIDENTIAL 53