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Emissions Reduction
Programs
by Nathan Long
Precipitators
Ohio Environmental Protection Agency (EPA) dictates opacity must be
below 20%. Other states may have different regulations.
Units 1-4
Each unit has a Joy/Western precipitator.
Consists of 16 fields powered by 8 transformer/rectifiers.
Neundorfer voltage and rapper controls.
Opacity averages between 5%-12%
Unit 5
Research Cottrell two boxes.
Each box has 30 rectified fields.
Neundorfer voltage and rapper controls
Opacity averages approximately 5%.
22
Precipitator Problems
Units 1-4
Casing leaks allows moisture to enter precipitator creating high levels of
sparking thus driving power levels down.
Transformer/rectifiers failing more frequently than in the past.
Reaching end of life?
Neundorfer controls aggresively ramp voltage back up following spark
quenching which may be shortening life of transformer/rectifiers.
Unit 5
Precipitators are oversized. No real problems.
33
44
55
66
77
Flue gas sample is diluted with air 300:1 to extend life of instrumentation and
make the system more reliable.
Monitors analyze the gas sample and send raw data to a polling computer which
calculates mass emissions rates.
The CEMS technician performs daily checks of the data before sending on to
AEP, Columbus. The data is submitted to the Ohio Environmental Protection
Agency on a quarterly basis.
Preventive maintenance is performed on the equipment on a quarterly basis.
Monitors automatically calibrate daily.
88
99
Terminology
Terminology
11 11
Overfire Air
_______________________________________________________________________
Secondary Furnace
overfire air
zone 2
Primary Furnace
12 12
thermal NOx
The lower peak flame temperature helps further reduce
the formation of thermal NOx
flame temperatures
13 13
Fuel-rich zone
Withholding air causes the cyclones to be operated fuel-rich. As
a result, CO is produced within the cyclone. In the lower furnace,
this CO aggressively reduces already formed NOx to N2 in its
attempt to form CO2.
The lower peak flame temperature provides an additional
incremental reduction in NOx.
Overfire air zone
Thermal NOx formation is limited due to lower gas and flame
temperatures.
14 14
C O E m issions
Oxidizing
0.85
1.0
1.15
Combustion
Zone Stoichiometry
Business Confidential
28
15 15
Atmospheric Nitrogen
[O2], temp.
NOx
Critical
Temperature
16 16
17 17
18 18
19 19
20 20
TM
Ammonia
-on-DemandTM
Ammonia-on-Demand
To
SCR
Dry
Storage
Preheater
Flash
Separator
Demin Water
Blower
Hydrolyzer
Mix Tank
Steam
Ambient
Air
21 21
22 22
l b/hr
60 F
0 psi
63 F
1 psi
6.28
Gas Inlet
5.98 In. H20 From Economizer
North
SCR Diff.
South
732.63 DEG F
SCR Diff.
Layer 1
30.07 PPM
Layer 2
NOx T rends
0.2
Layer 2
0.1
739.67 DEG F
732.47 DEG F
Layer 3
North Air Heater
AH Diff.
2.80 In. H20
GAS OUTLET
732.20 DEG F
Layer 3
Layer 4
GAS OUTLET
310.83 DEG F
304.83 DEG F
0.0
Layer 1
Calc. SO3 Leav ing SCR
Layer 4
5.60
Gas Inlet
From Economizer
739.94 DEG F
627 MWG.IPW
10/5/2006 1:33:21 PM
301 DEG F
731.42 DEG F
NOx 0.60 lb/Mbtu
% Remov al
8.9 % Remov al
North
Precipitator
South
Preci pitator
-3.83 In. H20
-3.40
-3.75
North
South
Booster Fan
Booster Fan
219 Amps
37 %
274 Amps
44 %
23 23
Typical Spray
Tower
Liquid is sprayed to
into Gas
Gas is sparged
into Liquid
Reservoir