process economics program - markit · process economics program abstract ... adjustable vortex...

PROCESS ECONOMICS

PROGRAM

Abstract

SRI INTERNATIONAL

Menlo Park, California

94025

Process Economics Progmm Report No. 200

NO, REMOVAL

(May 1999)

This report summarizes the current regulations for NO, abatement in the United States,

the European Community, and Japan. In that context, various NO, control process technolo-

gies and economics are evaluated, with emphasis on applications in the chemical industry.

Combustion control methods applicable to boilers, process furnaces and heaters, and

gas turbines include both burner and furnace modifications. Gas treating processes evalu-

ated include selective noncatalytic reduction, selective catalytic reduction for boilers, and

extended absorption for nitric acid plants.

PEP’88 ED0

a 0 m

Report No. 200

NOx REMOVAL

by EARL D. OLIVER*

May 1989

A private report by the

PROCESS ECONOMICS PROGRAM

Menlo Park, California 94025

l Under Contract with SRI International

For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMEAL ECONOMCS HANDBOOK

Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI D/RECTORY OF CHEMCAL

PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe

ii

Symbol

AGA AVC B&W BH BOOS CE CGCC DAF EC EDTA EER EPDC EPRI ER&E ESP FBC FD FGD FGR FGT FRO FW GE GFAVO GRI HMTA HRSG ID IFNR IFP IHI JM KHI KVB KW KWH LEA LIMB LNB MHI MM&u MW NFK

NO, NSPS OFA

Meaning

American Gas Association Adjustable vortex control (burner) Babcock & Wilcox Babcock-Hitachi Burners out of service Combustion Engineering Coal gasification/combined cycle Distributed air flow (burner) European Community Ethylene diamine tetraacetic acid Energy and Environmental Research Corp. Electric Power Development Company Electric Power Research Institute Exxon Research & Engineering Electrostatic precipitator Fluidized-bed combustion Forced draft Flue gas desulfurization Flue gas recirculation Flue gas treating Federal Republic of Germany: West Germany Foster Wheeler General Electric West German large source regulations Gas Research Institute Hexamethylenetetramine Heat recovery steam generator (for combined cycle plant) Induced draft In-furnace NO, reduction lnstitut Francais du Petrole Ishikawajima-Harima Heavy Industries Johnson Matthey Kawasaki Heavy Industries KVB, Inc. Kilowatts Kilowatt-hour Low excess air Limestone injection-multistage burning Low-NO, burner Mitsubishi Heavy Industries Million Btu Megawatts Nippon Furnace K.K. Nitrogen oxides (NO + N02) New Source Performance Standards Overfire air

. . . - Ill -

PFBC

PSD PURPA

RAP RS SCA

SCAQMD

SCFM SCR

SDG&E

SFA

SIP

SNR

STIG TA Luft

TFC

TP&MS

TVA

UBA

U.K.

USDOE USEPA

ton

t

Meanlna

Pressurized fluidized-bed combustion

Prevention of significant deterioration (of air quality) Public Utilities Regulatory Policies Act

Reduced air preheat Riley Stoker Staged combustion air

South Coast Air Quality Management District (in California)

Standard cubic feet per minute (1 atm., 60°F or 15.56)

Selective catalytic reduction

San Diego Gas & Electric

Side fire air

State implementation plan (in United States)

Selective noncatalytic reduction

Steam injected gas turbine

West German small source regulations

Total fixed capital

Turbo Power & Marine Systems

Tennessee Valley Authority

Umweltbundesamt

United Kingdom

United States Department of Energy

United States Environmental Protection Agency

short ton (2,000 lb)

metric ton

- iv -

CONTENTS

1 INTRODUCTION I...............,.......,....,... . . . . . . . . . . . . . . . . . . . l-l

a -

0

2 SUMMARY ......................................................... 2-l

NO, REGULATIONS AROUND THE WORLD ............................... 2-l

United States ................................................... 2-3

Europe ......................................................... 2-4

Japan .......................................................... 2-4

CHEMICAL INDUSTRY NO, CONTROL PERSPECTIVE ....................... 2-4

COMBUSTION CONTROL METHODS ..................................... 2-5

Boilers, Furnaces, and Process Heaters ............................. 2-5

GasTurbines .................................................... 2-7

Effectiveness of NO, Combustion Control Methods .................... 2-8

Economics of Combustion Control Methods .......................... 2-9

Selection of NO, Control Methods .................................. 2-10

Future Requirements and Options .................................. 2-l 1

GAS TREATING METHODS ............................................ 2-12

Gases to beTreated ............................................. 2-12

GasTreatments ................................................. 2-13

Effectiveness of Gas Treating Methods .............................. 2-13

Economics of Gas Treating Methods ................................ 2-14

Selection of Gas Treating Methods ................................. 2-l 6

Emerging Options for Gas Treating ................................. 2-17

3 INDUSTRY STATUS ................................................. 3-l

EMISSION ESTIMATES ................................................ 3-l

STATUS OF REGULATIONS ............................................ 3-4

Ambient Standards.. ............................................. 3-4

U.S. Emission Regulations ......................................... 3-5

European Emission Regulations .................................... 3-6

Japanese Emission Regulations .................................... 3-9

Local Regulations ................................................ 3-10

-v-

CONTENTS

3 INDUSTRY STATUS (Concluded)

STATUS OF NO, CONTROL SYSTEMS ..................................

Available Control Technologies .....................................

United States ...................................................

Western Europe .................................................

Japan ..........................................................

PRINCIPAL DEVELOPERS AND DEVELOPMENT PROGRAMS .................

United States ...................................................

Western Europe .................................................

Japan ..........................................................

3-l 1

3-l 1

3-l 1

3-14

3-15

3-17

3-17

3-19

3-20

4 COMBUSTION MODIFICATION AND BOILER DESIGN ..................... 4-l

FUNDAMENTALS OF NO, FORMATION .................................. 4-l

TYPES AND CAPACITIES OF INDUSTRIAL BOILERS ........................ 4-4

UNCONTROLLED EMISSIONS .......................................... 4-8

REVIEW OF OPERATIONAL CHANGES ................................... 4-9

Low Excess Air (LEA) ............................................ 4-9

Biased Firing .................................................... 4-11

Burners Out of Service (BOOS) .................................... 4-l 1

Reduced Air Preheat (RAP) ........................................ 4-12

Fuel Switching or Dual Fuel/Split Fuel ............................... 4-12

REVIEW OF EQUIPMENT MODIFICATIONS ................................ 4-l 3

Overfire Air (OFA) ............................................... 4-13

Flue Gas Recirculation (FGR) ...................................... 4-14

Low NO, Burners (LNBs) .......................................... 4-15

Reburning or In-Furnace NO, Reduction (IFNR) ....................... 4-20

REVIEW OF DESIGN CHANGES ........................................ 4-21

Conventional Furnaces.. .......................................... 4-21

Fluidized-Bed Combustion (FBC) ................................... 4-21

Coal Gasification/Combined Cycle (CGCC) ........................... 4-21

Combustion Modification Patents ................................... 4-22

EFFECT OF NO, REDUCTION ON COSTS ................................ 4-22

- vi -

CONTENTS

~ I I l

l

a

l

0

a

5 OTHER COMBUSTION PROCESSES .................................... 5-1

PROCESS HEATERS ................................................. 5-1

Types and Uses of Process Heaters ................................ 5-l

NO, Emissions and Control Testing ................................. 5-l

Prospective Control Requirements .................................. 5-5

Favored Control Systems ......................................... 5-6

Vendor Offerings and Approaches .................................. 5-6

Costs of Process Heater NO, Controls .............................. 5-8

GAS TURBINES ..................................................... 5-9

Types of GasTurbines ............................................ 5-9

Applications ..................................................... 5-10

Fuels .......................................................... 5-10

Baseline NO, Emissions ........................................... 5-l 1

Control Technology .............................................. 5-11

Wet NO, Control for Gas Turbines ............................... 5-11

Dry NO, Control for Gas Turbines ............................... 5-12

Flue Gas Treating ............................................. 5-14

Other NO, Reduction Systems ..................................... 5-15

Costs of Gas Turbine NO, Controls ................................. 5-16

6 SELECTIVE NONCATALYTIC REDUCTION ............................... 6-l

CHEMISTRY ........................................................ 6-2

REVIEW OF PROCESSES ............................................. 6-4

Exxon “Thermal DeNOx” .......................................... 6-6

EPRI/Fuel Tech NOxOUT” Process .................................. 6-8

Other Processes ................................................. 6-9

BASES OF DESIGN .................................................. 6-10

PROCESS DESCRIPTION .............................................. 6-l 1

PROCESS DISCUSSION ............................................... 6-l 5

COST ESTIMATES ................................................... 6-l 6

Capital Costs ................................................... 6-16

Operating Costs ................................................. 6-17

- vii -

CONTENTS

7 SELECTIVE CATALYTIC REDUCTION ................................... 7-l

CHEMISTRY ........................................................ 7-2


Basic Process.. ................................................. 7-3

Licenser Variations ............................................... 7-6

BASES OF DESIGN .................................................. 7-6

PROCESS DESCRIPTION .............................................. 7-9

PROCESS DISCUSSION ............................................... 7-13

COSTESTIMATES ................................................... 7-14

Capital Costs ................................................... 7-14

Operating Costs ................................................. 7-16

9 OTHER FLUE GAS TREATING PROCESSES ............................. 8-l

CHEMISTRY ........................................................ 8-l

Adsorption Process .............................................. 8-2

Noxso@ Process ................................................. 8-3

Sorbent Injection ................................................. 8-4


Activated Carbon ................................................ 8-5

Noxso@Process ................................................. 8-11

Sorbent Injection ................................................. 8-l 3

9 NITRIC ACID PROCESSES ............................................ 9-l

CHEMISTRY ........................................................ 9-2


Processes and Licensers .......................................... 9-5

Chilled Absorption ............................................... 9-6

Extended Absorption ............................................. 9-6

Wet Chemical Scrubbing .......................................... 9-6

Ammonia Scrubbing .............................................. 9-7

Caustic Scrubbing ............................................... 9-9

Potassium Permanganate Scrubbing ................................ 9-9

Nonselective Catalytic Reduction ................................... 9-9

.*. - VIII -

CONTENTS

9 NITRIC ACID PROCESSES (Concluded)

REVIEW OF PROCESSES (Concluded)

Selective Catalytic Reduction (SCR) ................................. 9-l 0

Adsorption ...................................................... 9-l 1

NO, Removal from Processes other than Nitric Acid Plants ............. 9-l 2

BASESOFDESIGN.. ................................................ 9-12

PROCESS DESCRIPTION .............................................. 9-l 4

PROCESS DISCUSSION ............................................... 9-l 8

COST ESTIMATES ................................................... 9-18

Capital Costs ................................................... 9-18

Operating Costs ................................................. 9-l 9

Appendix A: PATENT SUMMARY TABLES . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . A-l

Appendix B: CITED REFERENCES . . . . . . . . . . . . . . . . . m...................... B-l

Appendix C: PATENT REFERENCES BY COMPANY . . . . . . . . . . . . . . . . . . . . . . . . . . C-l

- ix -

ILLUSTRATIONS

4.1 CATEGORIES OF INDUSTRIAL BOILERS ............................. 4-5

4.2 RELATIVE DISTRIBUTION BY CAPACITY OF THE

THREE TYPES OF INDUSTRIAL BOILERS ............................ 4-6

8.1 FORMATION OF AMMONIUM SULFATE FOR VARIOUS

CONCENTRATIONS OF NH3 AND SOS ............................... 6-5

6.2 EXXON THERMAL DeNOx PROCESS ............................... 6-l 2

8.3 EXXON THERMAL DeNOx PROCESS EFFECT OF PLANT CAPACITY ON TOTAL FACILITIES COST ............ 6-19

7.1 BASIC EQUIPMENT LAYOUT OPTIONS

FOR PROCESSING FLUE GAS FROM A COAL-FIRED BOILER ............ 7-5

7.2 KHI SELECTIVE CATALYTIC REDUCTION PROCESS ................... 7-l 0

7.3 KHI SELECTIVE CATALYTIC REDUCTION PROCESS

EFFECT OF PLANT CAPACITY ON TOTAL FACILITIES COST ............ 7-23

8.1 FLOW DIAGRAM OF BERGBAU-FORSCHUNG AND UHDE PROCESS ...... 8-8

8.2 FLOW DIAGRAM OF NOxSO PROCESS .............................. 8-l 2

8.3 FLOW DIAGRAM OF SORBENT INJECTION ........................... 8-14

9.1 PROCESS FLOW DIAGRAM FOR THE GOODPASTURE PROCESS ......... 9-8

9.2 NO, REMOVAL EXTENDED ABSORPTION PROCESS ................................ 9-15

9.3 NO, REMOVAL

EXTENDED ABSORPTION PROCESS EFFECT OF PLANT CAPACITY ON TOTAL FACILITIES COST ............ 9-21

- xi -

2.1

0 2.2

l

2.3

2.4

2.5

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

3.11

3.12

3.13

3.14

3.15

3.16

3.17

4.1

4.2

TABLES

SUMMARY OF NO, EMISSIONS AND REGULATIONS ................... 2-2

EMISSION SOURCES AND COMBUSTION

MODIFICATION EFFECTIVENESS ................................... 2-8

ECONOMICS OF COMBUSTION MODIFICATIONS ...................... 2-l 0

EFFECTIVENESS OF GAS TREATING PROCESSES .................... 2-14

ECONOMICS OF GAS TREATING METHODS ......................... 2-15

GLOBAL DISTRIBUTION OF ENERGY DEMAND, 1975 .................. 3-l

EPA NO, EMISSION INVENTORY, 1977 ............................. 3-2

ANNUAL EUROPEAN NO, EMISSIONS .............................. 3-3

NO, EMISSIONS AND DENSITIES .................................. 3-3

AMBIENT STANDARDS FOR NO2 ................................... 3-4

USEPA NEW SOURCE PERFORMANCE STANDARDS

FOR lNDUSTRlALlCOMMERClAL/INSTITUTlONAL

STEAM GENERATING UNITS ...................................... 3-5

TARGET VALUES OF REDUCTION OF GLOBAL NO, EMISSIONS AND MAXIMUM EMISSIONS FOR LARGE “EXISTING”

COMBUSTION INSTALLATIONS .................................... 3-7

EUROPEAN COMMUNITY EMISSION LIMITS

FOR NO, FROM NEW PLANTS .................................... 3-7

NEW SOURCE EMISSION STANDARDS FOR NO,

IN WEST GERMANY FOR SMALL SOURCES .......................... 3-8

NO, EMISSION STANDARDS IN SELECTED EUROPEAN COUNTRIES ...... 3-9

JAPANESE EMISSION LIMITS FOR NO, ............................. 3-10

SELECTED LIST OF NONCATALYTIC REDUCTION INSTALLATIONS IN CALIFORNIA ......................... 3-12

SELECTED LIST OF SELECTIVE CATALYTIC

REDUCTION INSTALLATIONS ON INDUSTRIAL BOILERS AND HEATERS IN CALIFORNIA ............................ 3-13

SELECTIVE CATALYTIC REDUCTION SYSTEMS ON GAS TURBINE EXHAUSTS IN CALIFORNIA ........................ 3-13

WEST GERMAN FLUE GAS TREATING INSTALLATIONS, 1985-1988 ...... 3-14

APPROXIMATE USE OF FLUE GAS TREATING IN JAPAN ............... 3-16

INDUSTRIAL SELECTIVE CATALYTIC REDUCTION PLANTS IN JAPAN ..... 3-16

BASELINE NO, EMISSION FACTORS ............................... 4-8

EFFECTIVENESS OF LOW EXCESS AIR IN INDUSTRIAL BOILERS ........ 4-10

... - XIII -

TABLES

4.3

4.4

4.5

4.6

4.7

4.8

4.9

5.1

5.2

5.3

5.4

6.1

6.2

8.3

6.4

6.5

6.6

6.7

6.8

7.1

7.2

7.3

AVERAGE NO, REDUCTION WITH OVERFIRE AIR .....................

CORPORATE PARTNERS IN LICENSING AND/OR DEVELOPMENT .........

INDUSTRIAL BURNERS ...........................................

COMBUSTION MODIFICATIONS

PATENT SUMMARY .............................................

REBURNING

PATENT SUMMARY .............................................

COSTS OF NO, REDUCTION ......................................

COSTS OF NO, REDUCTION ......................................

BASELINE NO, EMISSIONS FROM REFINERY PROCESS HEATERS .......

SUMMARY OF PROCESS HEATER TESTS ...........................

BASELINE NO, EMISSIONS FROM GAS TURBINES ....................

NO, CONTROL FOR GAS TURBINES

PATENTSUMMARY .............................................

SELECTIVE NONCATALYTIC REDUCTION

PATENT SUMMARY .............................................

EXXON “THERMAL DeNOx” PROCESS

DESIGN BASES AND ASSUMPTIONS ...............................

EXXON “THERMAL DeNOx” PROCESS MAJOR EQUIPMENT .............................................

EXXON ” THERMAL DeNOx 1, PROCESS STREAM FLOWS.. ..............................................


TOTAL CAPITAL INVESTMENT .....................................

EXXON “THERMAL DeNOx” PROCESS EFFECT OF FUEL AND HEAT RELEASE RATE

ON TOTAL CAPITAL INVESTMENT .................................


PRODUCTION COSTS ............................................


EFFECT OF FUEL AND HEAT RELEASE RATE

ON TOTAL PRODUCT VALUE .....................................

SELECTIVE CATALYTIC REDUCTION PATENT SUMMARY .............................................

SELECTIVE CATALYTIC REDUCTION LICENSORS .....................

KHI SELECTIVE CATALYTIC REDUCTION PROCESS

DESIGN BASES AND ASSUMPTIONS ...............................

4-14

4-17

4-l 7

A-3

A-12

4-24

4-25

5-2

5-3

5-l 1

A-16

A-19

6-10

6-13

6-l 4

6-18

6-20

6-21

6-23

A-23

7-3

7-8

0 -

0

l - xiv -

-

a

7.4

7.5

7.6

7.7

7.8

7.9

8.1

8.2

9.1

9.2

9.3

9.4

9.5

9.6

9.7

9.8

TABLES


MAJOR EQUIPMENT . . . . . . . . . . . . . . . . . . . , . , . . . , . , , , . . . . . , . . , . . . . . . 7-l 1


STREAM FLOWS................................................ 7-12


TOTAL CAPITAL INVESTMENT . , . . . . . . . . . . . . , . . . . . . . , . . , . . . . . . . , . . , 7-18


EFFECT OF FUEL AND HEAT RELEASE RATE

ON TOTAL CAPITAL INVESTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19


PRODUCTION COSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 7-20


EFFECT OF FUEL AND HEAT RELEASE RATE ON PRODUCT VALUE . , . . , 7-22

ACTIVATED CARBON AND ADSORPTION

PATENT SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-33

SORBENT INJECTION PATENT SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-41

NO, CONTROL FOR NITRIC ACID PATENT SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-43

NO, REMOVAL PROCESSES FOR NITRIC ACID PLANTS . . . . . . . . . . . . . . . . 9-5

EXTENDED ABSORPTION PROCESS

DESIGNBASESANDASSUMPTIONS . . . . . . . . . . . . . . . ..a. . . . . . . . . . . . . 9-13

NO, REMOVAL


MAJOR EQUIPMENT . . .,.......................*.*............... 9-l 6

NO, REMOVAL


STREAM FLOWS, LBlHR , . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

NO, REMOVAL


UTILITIES SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-l 7

NO, REMOVAL EXTENDED ABSORPTION PROCESS TOTAL CAPITAL INVESTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

NO, REMOVAL EXTENDED ABSORPTION PROCESS PRODUCTION COSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . g-22

-xv-

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