RecentCoalFiredSCROperatingExperienceintheUSA26-2clo:·u5:·s;::o:(\JI'Cl1n!:::i:-o:C:-oic:CCI!,._f<l>i~:~lRecentCoalFiredSCR OperatingExperienceintheUSAPresentedto2001EPRISCRWorkshopSpecialThanksto:AES,B&W,CP&L,FWandKCP&LJohnCalvelloHitachiAmerica,Ltd.HITACHIilnspiretheNe,cl~E'RecentCoalFiredSCROperatingF.xperienceintheUSA61·u51·;;1oicolii-oiCi-olc,co,,-j~IO,CL/BHKSCRSystemApplicationandExperienceFiredBoiler•BOILER•FURNACE•COKESOVEN.----·HITACHI1lnspiretheNe,c\:12E26-3RecentCoalFiredSCROperatingExperienceintheUSA26-4dO!·wi·;;ioi(ill·;:::j......i~I"O!C,-gj('(l!mi~lO!CL••LatestCoalFiredSCRSystemsCurrentlyOperatingwithHitachiPlateTypeCatalystintheUSA-AES,Somerset,July1999-BituminousCoal-Medium-HighSulfur-HighDust,PCFired-CleaningviaSteamSootblowing-CP&LRoxboro#4,July2001-BituminousCoal-LowSulfur-LowDust,PCFired-CleaningviaAcousticHorns-KCP&LHawthorn,May2001-Sub-BituminousCoal(PRB)-HighDust,PCFired-CleaningviaAcousticHornsHITACHIlInspiretheNexlRecentCoalFiredSCROperatingExperienceintheUSAOutlineofHitachi6.0mmPlateTypeCatalyst§!:~1CATALYSTELEMENT0i(Thickness:Approx.0.9mm)C\l!·-j!:;!(/)!:::::,!·c:i:ClCATALYSTUNIT-oiClCtl](Size:Approx.500x500x500(mm))...Q)0Cl...·-·---·--····----·-··------------------CATALYSTBLOCKHITACHI1lnspiretheNexl,4E26-5RecentCoalFiredSCROperatingExperienceintheUSA26-6ciol·u5!~!<tli·cl,+-Ji(/)!:Ji-glAESSomerset-675MWSCAProjectCompletedin1999)SuppliedCourtesyofBabcock&WilcoxiHITACHII.lnspiretheNex\:lsE1d.QI-~iot.~!~I:Ji-o!c!·olffi!~i(l)i>iclo..jAESSomerset675MWSCRSystemAirHeaterExistingStructuralSteel--..··--·--·-···-·----RecentCoalFired SCROperatingExperienceintheUSADamperSCRAmmoniaSealAirBypassInjectionSystemPipingtFromAmmoniaStorageSystemSCRReactorCatalystLayer--ti----FutureFutureCataly,it....ToPrecipitatorNewStructuralSteelHITACHI,lnspiretheNext1iiE26-7RecentCoalFiredSCROperatingExperienceintheUSAAESSomersetCoalAnalysisCoaldataforAES/Somerset26-8cl01:~1olcrii·ci........!(/)J::ii'"OJC-glro:....iQ):~ioia..!HeatMoistVolFCAshsCHN0ClSi02Al203Fe203Ti02P205CaoMgONa20K20S03AsBaMn.---------BTU/Lb(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)PPMPPMPPMAverageMaxMin1302313237125505.876.185.5337.0540.0935.649.4952.0344.797.889.156.672.414.121.4171.9074.3668.414.905.214.691.311.531.146.477.25.630.120.140.0746.4451.342.8122.3126.1819.2818.2628.7912.60.961.170.870.280.440.044.205.922.610.840.980.670.530.70.421.371.491.24.967.183.054.446.732.775.9310.950.215.5921.0510.92HITACHI:1nspiretheNextAESSomersetCatalystDesignParameterscl-~I'>ioi(illE!(/)!::ii-gl-oiCi(Of~!Cl)!3:!o:Q._jSizeFuelConfigurationOperationCommercialOperationGasFlowGasTempNOxInlet02H20S02DustNOxOutletDeNOxEfficiencySlipCatalystVolumeGasVelocityS02toS03ConvPressureDropCatalystLife-----------·-----675MWBitCoalHighDustOzoneSeasonJuly19996,500,000lbs/hr649F340ppm3%7%1140-3490ppm5gr/dscf34ppm90%3ppm897m36.0mis<0.75%2.8inwg24,000hrRecentCoalFiredSCROperatingExperienceintheUSAHITACHIrlnspiTetheNex~!se26-9RecentCoalFiredSCROperatingExperienceintheUSA26-10AESSomersetCatalystCleaning•SteamSootblowersprovidedforonlinecleaning•OperatedOnceperWeek•CatalystRemainsClean•NoIncreaseinPressureDropObserved•Nomanualcleaninghasbeenrequiredatanytime5j•Nobuildupofashoncatalysthasbeenobserved·u51•>ioicoi.i:::.+-Ii~!"Oic:-oiCico:a5!~IOiCL.-------HITACHIiInspiretheNexttsERecentCoalFiredSCROperatingExperienceintheUSAAESSomersetCatalystjqo•·u5!'>io!co:·-1'-l+-1~I-g1~1ia3i;::!o!O..i-·-·--.--SomersetCatalystafter2ozoneseasonsofoperation.Max.designgasvelocityatcatalystfaceis23.6ft/s(6.0m/s).HITACHIIlnspiretheNextIO26-11RecentCoalFiredSCROperatingExperienceintheUSA26-12§I·u51~!-~!tj/-5jCj-olC!ctl!~i0)13:!~!AESSomersetCatalyst•Noerosionandnodustplugginghasbeenobserved.---HITACHI1InspiretheNexl!1dot·-1·~I·-ID('j!·.::!cnl:Ji"0!c!.,....!'-''§i'-IQ)!~Ioia..1•RecentCoalFiredSCROperatingExperienceintheUSAAESSomersetCatalystDeactivation-ExpectedvsActualI-Design(Expected)•SomersetI-I-1.210.80.60.40.20I········...···-:·······································.....,...............,-lKO=DesignInitialActivityI0500010000 15000200002500030000OperatingTime(h)HITACHIilnspiretheNext~226-13RecentCoalFiredSCROperatingExperienceintheUSA.~,'>I01(\jl~I-5!c!CP&LRoxboro#4SCRReactorBeganOperation:July2001d-Ci(\jjL.!Q)'~I-~~~~~~====::::::CLIllHITACHIlInspiretheNex\:13126-14-RecentCoalFiredSCROperatingExperienceintheUSACP&LRoxboro#4-ArrangementofFlues&SCR~__.---------fl-[l.af~]'.'___itsh,a,:-~!(JaSTIHCrtUCPlrCOPIT•IOII\,,.......,,.,T-~I~---------------------!·-........-·t..........•/".I.....__,.-1........._..........I_,.-....._I_,.-....._I__.,,-..........---V VVVHITACHIInspiretheNexl:~426-15RecentCoalFiredSCROperating&perienceintheUSA26-16cloi:~1ol<'tl!·ci+-Ji~!"O!Ci_;·oiCJ<'tli1-.lO)i3!:iOiO..iIICP&LRoxboro#4ArrangementofFlues&SCRr=r-·11·---~ff·--T,---111iiIIii11iiiiii11··1IU_I I_JJI'!ILL'I Iiii'~-:-~~,__~-gS_~--~--. .,,~-----==h4-I',i~/~-'..2:.'~------~:1'"/.;.:i~':/::::,::::.,_.''..','',,/::...,~-:::_____[____::-~-'v:'V.-...--c,--------,----,---._------------------------,,'·-;_::...-----~~··-f..:r,_f'.'.'.:.f''"========cc===-==f3::::::::'.•·:,1IjI I,,r~D~--*--.__,,1·::""-...-----~i--i--+---i-J____j__j__~_,_c_·1:-_<>.~j:'~!ff!¥iijij~.:~~-~I1'··::~·1.;--.:..~.:··:--···--:--'!l-------1I'---+I I IIi.,________i________---------.---.-----'-'---.,i·'I'-.'·--:..:i----E-------=i-1=----!----1-11,·---:":i--------,··:-----,-,---:'i..U:I~:.l\·:~::l\:·7,::l\::~---_l\·_:=;Ji'·vv·v:·v·v·v,'v,'·.v:-.v:-.v:'-v,'·v:-.v:11-------·----HITACHI1lnspiretheNexlisiRecentCoalFiredSCROperatingExperienceintheUSACP&LRoxboro#4-ArrangementofFlues&SCRcioi:@>ioictll·d_.!(I)[:Ji-oiC!-oiC:ctl:1-!IDi~io:CL.-t·----·-·-----·-·_..._._____I_________IDD Da aD Ds======s>FFvulIDaDD DrP-..r"--,.._,,,~--~~--~i iL..J1!:'~J~9~!~~626-17RecentCoalFiredSCROperatingExperienceintheUSACP&LRoxboro#4CoalAnalysisCoaldataforRoxboro#426-18§I·u5;~ico!El(/)\:::r"O!Ci-:-o!c:Ctli'"-iQ)j3:iOiO..i•HeatMoistVolFCAshsCHN0ClSi02Al203Fe203Ti02P205CaoMqONa20K20S03AsBeMnMaxBTU/Lb13,500(%)3(%)28(%)45(%)5(%)1.5(%)80(%)6(%)1.7(%)8(%)0.1(%)70(%)38(%)25(%)3.5(%)0.6(%)10(%)8(%)4.0(%)3.0(%)1 0PPM12PPM3PPM78Min10,5001139551 70.46041.020.011 0820.40.10.50.30.10.10.1000HITACHIilnspiretheNexlCiO!:~1>1o!-~I<ni:Ji-OiCl-o:C:(tl!,-l!IO..iIIRecentCoalFiredSCROperatingF.xperienceintheUSACP&LRoxboro#4-CatalystDesignParametersSize735MWFuelBitCoalConfigurationLowDustOperationOzoneSeasonCommercialOperationJuly2001GasFlow1,206,000Nm3/hr/1,725,300ACFMGasTemp735FNOxInlet278ppm023.25%H206.5%S02630ppmDust100mg/Nm3NOxOutlet58.5ppmDeNOxEfficiency79%Slip2ppmCatalystVolume314.8m3GasVelocity6.0misS02toS03Conv<1.0%PressureDrop1.3inwg(33mmH20)CatalystLife24,000hr-----------.HITACHIlnspiTetheNe"\:as:26-19RecentCoalFiredSCROperatingExperienceintheUSAdO!·wi·>!olcol·;::I-1(J)I:JI1::itCf-olc:Ctli~1(l)j3iola..:Roxboro4HitachiCatalyst.-----------------------------------------1HITACHIiInspiretheNe>ct:~9126-20CP&LRoxboro#4CatalystCleaning•LowDustSCRsystem•BHAAcousticHornsUtilizedforonlinecleaning•EightHornsPerReactor•4SonicHornsarelocatedaboveeachcatalystlayer•NoincreaseofSCRpressuredrophasbeenobserved§I•Nomanualcleaningisanticipated'u5i'>ioirui·-•Zi(/)i::l!-o:Ci-olc:('()/c5!3:~i.---------RecentCoalFiredSCROperatingExperienceintheUSAHITACHI(lnspiretheNe,cl26-21RecentCoalFiredSCROperatingExperienceintheUSAcio:·u51~ico!·;::!tii::Jit:llCi-olCico!AccousticHorns-Roxboro4Q)j3:!rl•HITACHIIlnspiretheNext:~126-22RecentCoalFiredSCROperatingExperienceintheUSACP&LRoxboro#4PerformanceTestResults•PerformanceTestResults•DesignNOxRemovalof79%hasbeenachieved:MinimumLoadAmmoniaSlip:0.1ppmFullLoadAmmoniaSlip::0.4ppmc!•S02toS03OxidationRateOi·u51·;;::oi<1%hasbeendemonstratedco!t51•PressureDrop::Ji"O!C!-0:CiCOi~,0)13:IO!CLIIDataUnavailableHITACHI:lnspiretheNext26-23RecentCoalFiredSCROperatingE.xperienceintheUSAKCP&L'sHawthornUnit5 -June2001HITACHIllnspiretheNe"t26-24cl-~I·;;,o!<'Oi·ci.....,~I-o'cl-!"Otc:coll,,...[Q)!~iOicuIIHawthornUnit5 SdeView1'1iIIII'III----------·---RecentCoalFiredSCROperatingExperienceintheUSA•4,000,000lb/hr•2600psi,1005F/1005F•(2520,1000F/1000F@turbine)HITACHI(lnspiretheNexti426-25RecentCoalFired SCROperatingExperienceintheUSAKCP&LHawthornCoalAnalysisCoaldataforHawthorn26-26J01·u51·:=.;::oicoI'Ci..-!(/)i:::i:-o,C!"O:c:CO\~I01CL/··---HeatMoistVolFCAshsCHN0ClSi02Al203Fe203Ti02P205caoMqONa20K20S03AsBaoMnBTU/Lb(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)(%)PPMPPMPPMAverageMin8350810030.629.031.128.832.830.55.5 4.60.330.2348.046.33.43.10.70 0.611.5-0.010.0033.027.915.513.26.0 3.61.30.81.71.022.517.64.0 1.71.40.40.30.013.010.1- -----Max860032.233.435.96.40.4349.63.70.8-0.0238.117.88.4.1.82.427.46.32.40.615.9---HITACHIlInspiretheNext:KCP&LHawthorn-SCRDesignParametersC0·u5·;;0<tli·;::1...,.;(/)!::>!,:rc:"0'C,ro:1-f~!OiQ_i.------SizeFuelConfigurationOperationCommercialOperationGasFlowGasTempNOxInlet02H20S02DustNOxOutletDeNOxEfficiencySlipCatalystVolumeGas VelocityS02toS03ConvPressureDropCatalystLife500MWSubBit CoalHighDustContinuousMay20015,595,000lbs/hr695F135ppm3.5%13.6%420ppm32710lbs/hr59.2ppm55.6%2ppm477m35.7mis<0.75%2.0inwg24,000hrRecentCoalFiredSCROperatingExperienceintheUSAHITACHI.lnspiTetheNext2626-27RecentCoalFiredSCROperatingExperienceintheUSA26-28CiOi·w:KCP&LHawthorn-CatalystCleaning•HighDustSCAsystem•PCFired(HighAshLoading)•SHAAcousticHornsUtilizedforonlinecleaning•EightHornsPerReactor•4SonicHornsarelocatedaboveeachcatalystlayer•Catalysthasremainedveryclean•NoincreaseofSCRpressuredrophasbeenobserved~!•Nomanualcleaningisanticipatedcol·er+-i(/);:Ji-oiCi-o!ClCtlii-1!ICl.iIllHITACHI\lnspiretheNex~i:cloi:~1>!oico!·c:.....1(l)i::ii-gl§!,-(ar~iO!0..i•AccousticHorns-KCP&LHawthornRecentCoalFiredSCROperatingExperienceintheUSASuppliedCourtesyofB&WandKCP&Lx!HITACHIIlnspiretheNext~,26-29RecentCoalFiredSCROperatingExperienceintheUSAKCP&LHawthorn-CatalystPerformance•SCATuningisCurrentlyOn-going•PreliminaryDataIndicatesGuaranteedPerformanceisbeingAchieved26-30do:·u5j~!(0:-~;..-1(1),:::i,"01C!-o:§Ia5i3:io!Cl..!·===-----HITACHIIlnspiretheNex\:!191RecentCoalFiredSCROperatingExperienceintheUSAHitachiCatalystFormulationsforCoalFiredApplications•FourBasicFormulationsOffered•C3,C2,C1,andCO•C3Catalyst•MostReactiveCatalyst•LowestCatalystVolume•HighestS02toS03OxidationRate.•WorkswellatrelativelyLowTemperaturec/•C2andC 1CatalystQl'ci51'>ioienl·c1•LessReactivethanC3•LowerS02toS03OxidationRatethanC3catalyst•WorkswellatMediumTemperatures~!•COCatalyst"'O,C-i•VeryReactiveatHighTemperature-g1iiQio...l•ReactiveDrops offQuicklywithLoweringTemperatures•LowestS02toS03OxidationRate•WorkswellatrelativelyHighTemperatures.------HITACHIIlnspire theNex\:~126-31RecentCoalFiredSCROperatingExperienceintheUSACaseStudy-ComparisonofHitachiCatalystFormulations26-32clO::~1oi<'Cll·.51(/)j:::ll-0:Cj-oiC:Ctl:~1Q):s:!0/CL!•90%NOxRemoval,2ppmSlip,16,000hourslifeTemperatureC3C2CatalystCatalystCase1Volume700FXaxS02->S031.2 1.0Case2Volume750F- -S02->S03- -Case3Volume780F- -S02->S03- -Note1:a<<y'-------Note2:8<1Note3:£<1C1coCatalystCatalyst~xyx0.6 0.5y8y1.00.5zcZ1.40.5HITACHIIInspiretheNext~iJ0:·wi~!<'u[·-,,._'+-!(J)'::::i!"0/C!~I~i(l.)!RecentCoalFiredSCROperatingExperienceintheUSAConclusions•USExperiencewithHitachiPlateTypeCatalystisExcellent•SCRConfigurationsHighDustLowDust•FuelsBituminousCoalSub-bituminousCoal(PRB)•SulfurHighSulfurLowSulfur•CatalystStaysCleanSootblowersSonicHorns•S02toS03OxidationRateTailoredtoRequirements~~--------------·----------···---·-·•-••·----·•-••P•q---~---------------HITACHIIlnspiTetheNext~26-33