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NOx REDUCTION CAPABILITIES

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Evaluated SCR, LNB, FGR & SNCR for Boilers ... Boiler Revamps. Ultra Low NOx Burner Application. SCR Application. SNCR Application ... – PowerPoint PPT presentation

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Title: NOx REDUCTION CAPABILITIES


1
NOx REDUCTION CAPABILITIES
FOSTER WHEELER
2
NOx Reduction Techniques in Boilers and Process
Heaters for Refineries and Chemical Plants
3
The FW Advantages...
  • Experience and expertise on all low NOx
    combustion and post combustion systems.
  • Full turnkey unit/system capability
  • A philosophy of providing our clients with the
    highest value low NOx solutions.

4
Relevant Project Experience
  • NOx RACT (Northeast, CA)
  • New Source/Non-Attainment Area Reviews
  • Offset and Bubbling Analyses
  • Excess Allowance Generation and Sale
  • Installed Systems
  • Burners Several Thousand
  • SCRs 120
  • SNCRs 10

5
Refinery NOx Reduction
  • Refinery Wide - Process Heaters, FCCU Boilers.
  • Refinery Emission Cap
  • Evaluated SCR, LNB, FGR SNCR for Boilers
  • Evaluated ULNB, LNB, SNCR and SCR for Process
    Heaters
  • SCR System for Boilers gas/oil fired
  • ULNB for major Process Heaters

6
NOx Reduction Technologies
  • Selective Catalytic Reduction (SCR)
  • Ultra Low NOx Burners (ULNB)
  • Process Efficiency Improvements
  • Cogeneration
  • Heat Integration
  • Yield Improvements
  • Selective NonCatalytic Reduction (SNCR)

7
NOx Reduction Technologies
  • Premix Burners (Gas Turbines)
  • NO oxidation/absorption
  • SCONOx (Catalytic)
  • Reburning
  • Low Btu Fuel Gas
  • Fuel Segregation

8
Ultra Low NOx Burners
  • Use Staging
  • Use Flue Gas Recirculation
  • Commercial Available
  • Boilers
  • Process Heaters

9
Ultra Low NOx Burners Capabilities
  • Process Heaters
  • 20 vppm to 30 vppm
  • 0.025 to 0.04 lb/MMBtu
  • Boilers
  • 20 vppm to 30 vppm
  • 9 vppm commercially demonstrated

10
Technical Considerations
  • Restricted flame stability envelop
  • Tighter control required
  • Response suffers
  • Flame lengths
  • Burner Foot Print
  • Tightness of Setting

11
ULNB Vendors
  • Process Heaters
  • John Zink Zeeco
  • Callidus Hamworthy
  • Boilers
  • Todd
  • Coen

12
Add-On Controls
  • SNCR - High Temperatures (1600 - 2000F)
  • SCR (300 - 800 oF)
  • NO Oxidation

13
Selective Catalytic Reduction
  • Catalyst
  • High Temperature gt750 F
  • Intermediate Temperature 550 - 750 F
  • Low Temperature lt550 F
  • Ammonia Reducing Agent
  • gt90 Reduction

14
Shell Low Temp SCR
  • 325 to 680 oF
  • Highly Reactive Catalyst
  • Shaped Catalyst (Spherical Balls in Modules)
  • Applied Following HRSGs
  • Applied to at least one Reformer Furnace
  • 375 oF

15
SCR Technical Considerations
  • Temperature
  • Fuel Impurities
  • Ammonia Slip
  • Pressure Drop
  • Flue Gas Velocity/Concentration Distributions
  • NOx Removal Requirements

16
COST DISTRIBUTION OF TYPICAL SCR EQUIPMENT
PURCHASES
Catalyst
Other
Gas Analyzers
NH3 Skids/Grids
Sootblowers
Struct. Steel
IC
NH3 Storage
Reactor
Flues/ Ducts
17
SNCR
  • Temperature (1600 to 2000 oF)
  • Ammonia or Urea
  • 25 to 60 Removal Typical
  • Multiple Injection Points

18
SNCR Technical Considerations
  • Temperature
  • Profile through unit at different loads
  • Multiple injection points
  • Flue Gas Velocity/Concentration Distributions
  • NOx Removal Requirements

19
SCONOX
  • Oxidation/Absorption Catalyst
  • NO 1/2 O2 NO2 (Ox.)
  • 2 NO2 K2CO3 KNO3 KNO2 CO2 (Abs.)
  • KNO3 KNO2 CO2 4 H2 K2CO3 4H2 N2
    (Regen.)
  • Synthesis Gas Generator (H2 CO2 )
  • Applied to Gas Turbines
  • 2 to 3 vppm _at_ 15 O2

20
Summary
  • Multifaceted Approach Required
  • ULNBs
  • SCR
  • Premix Burners (GT)
  • SCONOX
  • Fuel Segregation
  • Energy Conservation

21
PROJECT PROFILE
  • Owner - L.A. Basin Refiner
  • Regulations - SCAQMD Rules 1109 1146
  • Fired Heater Contract
  • Mission - minimize cost impact to Owner for
    compliance with NOx regulations
  • Screening Studies
  • Investigate schemes
  • Prepare scope and cost estimates
  • Frequent interface with Owner

22
PROJECT PROFILE
  • Project Execution
  • Select schemes
  • Proceed with detailed design, engineering and
    procurement
  • Frequent interface with Owner
  • Results
  • Foster Wheeler, Owner and burner supplier
    co-developed improved low NOx burner designs

23
PROJECT PROFILE
  • One of five Rule 1109 heaters fitted with SCR
  • Four Rule 1109 heaters met regulations with low
    NOx burner retrofits
  • All Rule 1146 heaters - low NOx burners
  • Mission Accomplished

24
Program Implementation Resources
Environmental Services
Equipment Services
Design Installation
Front End Loading
  • Furnace Revamps
  • Boiler Revamps
  • Ultra Low NOx Burner Application
  • SCR Application
  • SNCR Application
  • NOx Reduction Studies
  • New Source Review / Non-Attainment Reviews
  • Bubbling/Offsets
  • NOx Credit Generation
  • Permitting Assistance
  • Detailed Engineering
  • Procurement
  • Constructability/Operability
  • Construction Management
  • Technology Selection
  • Design Specs
  • Budget Estimates
  • Implementation Plans
  • EPC Schedule

25
Approach
  • Team Approach / Team Building
  • Program Management Philosophy
  • Resource Management
  • Optimize Interface / Coordination with Operations
  • Incorporate Constructability / Operability
    Reviews

26
Key Activities
  • Identification/Categorization of Opportunities
  • Brainstorming - Challenge the Process
  • Study Options/Alternatives
  • Preliminary Cost Estimates/Economic Analysis
  • Recommendations/Technology Selection
  • Funding Quality Estimates
  • Approval to Implement
  • Design/Procure/Install
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