gas turbine scr performance optimization and … mp290 gas turbine scr performance optimization and...
TRANSCRIPT
![Page 1: Gas Turbine SCR Performance Optimization and … MP290 Gas Turbine SCR Performance Optimization and Management T. D. Martz, L. J. Muzio Fossil Energy Research Corp. Laguna Hills, CA](https://reader034.vdocument.in/reader034/viewer/2022051600/5aaa2bcd7f8b9a77188dc8a3/html5/thumbnails/1.jpg)
MP2901
Gas Turbine SCRPerformance Optimization and
Management
T. D. Martz, L. J. MuzioFossil Energy Research Corp.
Laguna Hills, CA
McIlvaine Hot Topic HourFebruary 14, 2013
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MP290
Gas Turbine SCR Systems
2
Simple Cycle GT SCR
750-850°F
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MP290
Gas Turbine SCR Systems
3
Combined Cycle GT SCR
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MP2904
Today’s Gas Turbine SCR Topics
• Troubleshooting- FERCo is a trusted 3rd party engineering services company- Extensive background with SCR (design, modeling, full scale testing)- Developed a process model for SCR design and troubleshooting
• Catalyst Inlet NH3/NOx Distribution and AIG Tuning- Why NH3/NOx distribution is important- How AIG tuning can extend catalyst life- FERCo’s approach to AIG tuning
• SCR Catalyst Management- What is it?- How is it done?- Why is it done?
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MP290
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NOx, ppm
NH
3-sl
ip, p
pm
Compliance Test
ComplianceWindow
Troubleshooting
5
NH3 slip is too high…Why?
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MP290
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0 2 4 6 8 10 12 14 16 18 20
NOx, ppm
NH
3-sl
ip, p
pmCompliance Test
ComplianceWindow
Why?
6
Catalyst Activity (K)?
Reactor Potential?
Flue GasBypass?
Poor NH3/NOx Distribution?
• F(material, geometry)• Condition of active sites
• Ability of the catalyst bed to reduce NOx• RP= K * Asp* Vcat/ Qfg
• Uniform NH3/NOx profile is critical• Local NH3/NOx >1 creates NH3 slip
• Any leakage around the catalyst increases stackNOx & NH3
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MP290
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0 2 4 6 8 10 12 14 16 18 20
NOx, ppm
NH
3-sl
ip, p
pm
Compliance TestExpected (RMS=10%)RMS=30%Bypass
Activity, NH3 Distribution, or Bypass?
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• FERCo utilizes a process model to compare expected SCR performanceto actual performance (see curves below)
• A single data point is not sufficient for identifying the problem
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MP290
Perform Additional Tests
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NOx, ppm
NH
3-sl
ip, p
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MP290
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0 2 4 6 8 10 12 14 16 18 20
NOx, ppm
NH
3-sl
ip, p
pm
Compliance TestExpected (RMS=10%)RMS=30%Bypass
Flue Gas Bypass?
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NH3 slip at high NOxsuggests flue gas bypass
Poor NH3/NOx distribution does not explain NH3 slip at high NOx levels
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MP29010
Catalyst Inlet NH3/NOx Distributionand AIG Tuning
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MP290
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70 80 90 100NOx Reduction, %
NH3 Slip, ppm
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NH3/NOx Distribution and AIG Tuning
New Catalyst
Near CatalystEnd-of-Life
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70 80 90 100
NH3 Slip, ppm
RMS=5% RMS=10% RMS=15% RMS=25%
Catalyst Aging
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MP29012
Sample Probe Grid Expedites Tuning
• AIG tuning is difficult withouta probe grid at the catalyst exit
• The costs for installing a probegrid will be recovered in the longrun:- No scaffolding or manlift required for
testing ($, safety issues)- Reduced test times (no manual probe)- Reduced testing contractor costs- More data
50MW simple cycle SCRWith a grid of 50 sample probes(5 x 10)
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MP29013
Sample Probe Grid Expedites Tuning
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MP29014
Sample Probe Grid Expedites Tuning
A sample grid is especiallyimportant for larger units(e.g., more than 30’ wide)
325MW combined cycle SCRwith a 36-point sample grid(6 x 6)
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MP29015
FERCo’s Multipoint Instrumentation
- Samples 48 points in 15 minutes- NOx and O2
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MP29016
• Some systems have no AIG adjustment valves – bad idea! No flexibility to account for 1) duct velocity gradients, 2) duct NOx gradients, or 3) lance-to-lance ammonia flow gradients
• Most systems have one-dimensional adjustability
• Ideal design: multiple zone adjustability
AIG Design Influences Tuning
Multiple zones allow treatment oflocalized gradients
NH3Vertical adjustability can handle only vertical velocity or inlet NOx gradients
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MP29017
AIG Tuning, 10 MW Gas Turbine SCR
As-Found Adjusted
0 2 4 6 8
Duct Bottom (ft)
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Nor
th W
all (
ft)
0.70.750.80.850.90.9511.051.11.151.21.251.31.351.41.451.51.55
Riverside Springs Unit 4 SCRBaseline NH3/NOx Distribution,
Catalyst Inlet
RMS = 22%
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Duct Bottom (ft)
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th W
all (
ft)
0.70.750.80.850.90.9511.051.11.151.21.251.31.351.41.451.51.55
Riverside Springs Unit 4 SCRNH3/NOx Distribution, Adjustment #1
Catalyst Inlet
RMS = 13%
NH3/NOx Distribution NH3/NOx Distribution
One-Dimensional,Vertical AIG
NH3
Adjustments across the widthnot possible
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MP29018
AIG Tuning, 350MW Combined Cycle SCRAs-Found Outlet
NOx (ppm)Optimized Outlet
NOx (ppm)
0 5 10 15 20 25Duct Bottom (ft)
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Wes
t Wal
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Wes
t Wal
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NH3 consumption reduced by 5%
One-Dimensional,Vertical AIG
NH3
Adjustments across the widthnot possible
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MP29019
Duct Burners Impact AIG TuningDuct Burners Off(Inlet NOx ppm)
Duct Burners On(Inlet NOx ppm)
AIG Tough to Tune
NH3
0 5 100
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0 5 100
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MP29020
AIG Tuning, 10 MW Gas Turbine SCR, 90° Turn
0 2 4 6 8 10 12 14 16 18 20 Width (ft)
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Hei
ght (
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Hei
ght (
ft)
As-Found AdjustedNormalized NH3/NOx Distribution
Multiple zones,skewed basedon flow modeling
RMS = 32% RMS = 13%
Normalized NH3/NOx Distribution
Corners adjusted
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MP29021
SCR Catalyst Management
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MP29022
SCR Catalyst Management
• What is catalyst management?- Keeping track of catalyst activity to ensure continued compliance
• How is catalyst management done?- Periodically determining the activity of the catalyst in the reactor- Laboratory analysis (if a sample can be obtained)- In situ analysis (later discussion topic)- Utilize catalyst management software for planning
• Why is it done?- Forecast when catalyst additions or replacements are necessary- Provide sufficient lead time to procure catalyst (6-9 months)
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MP29023
Catalyst Activity Degrades With Time
0.0
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K/Ko
NH3 Slip, p
pm
Operating Hours
NH3 Slip‐Model K/K0
Monitoring ammonia slip is also critical
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MP29024
In Situ Catalyst Activity Measurement*
Traditional Lab Measurement• Typically one per year• Currently no test protocol
KLab = -AVdesign ln(1-ΔNOx)Lab
@NH3/NOx=1-1.5
FERCo’s CatalysTrak®*
• in situ measurement• No outage required
KIn-situ = -AVactual ln(1-ΔNOx)full scale@NH3/NOx>1 locally
* Patented Process
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MP29025
Questions?
www.ferco.com