o

Competitive Power College

PowerGen 2005

Selective Catalytic Reduction: From

Planning to Operation

~NERGY I*_r..... ' ...................

. M.rnv s..lul""r~ •.Ollr PIIIJOlb<'

Presented By

SCOll Siraighi. Director of Project Engineering - LG&E EllL'rgy

Joe Stril-kland. Senior Projecl Engineer - LG&E Encrg)

Ju\cph Langone. Vice Presidem of BU',ine~s Development. B:lbcocl.. Pnwa

r-.lichae1 Kelly. Program Director - Babcock Po.... c:r

CIa} IOn Erickson. Director of Process Engineering - Ralx:tK:\.. I'll\\ cr

~Iichael Jasinski. Procc.'>s Engineer - Bahcock POWl'T

l.G8It=NERGY

t._r..... '_'...........
Competitive Power College

Agenda

PowerGen 2005

• Planning

• Capital Cost Estimating

• Design

• Construction, Commissioning, and Testing

• Operation

• Maintenance

~NERGY

Competitive Power College

a Sucpessful

allati n

PowerGen 2005
Compclitive Power College PowerGen 2005

SCR Construction Sequence Model (Movie)

• t't.

~NERGY

Competilive Power College • , PowerGen 2005

SCR Capital Cost Estimating Categories

1. Engineering

2. Piling & Foundations

3. Structural Steel

4. SCR Reactor, Ductwork & Expansion Joints

5. Isolation/Control Dampers

6. Catalyst

7. Catalyst Cleaning Systems

8. Ammonia Storage ard Feed Systems

9. Dilution/Seal Air Systems

10. Electrical/Instrumentation & Controls

~NERGY

23
Competitive Power College

Engineering

PowerGen 2005

~.

,","

,..

... :: I

2D,0

.,.

".0

".0

§ 12.0

10.0

••

..

••

..

•• - (:)

.....

_500 ..... 1011 ..... _'_

Unit SI:z. (MWJ

~NERGY

Compelilive Power College

Piling & Foundation Systems

PowcrGen 2005
Competilive Power College PowerGen 2005

"'j ..

..

..

••

••

Foundations & Site Work

.....

,.

lblx;ock~

l ... V1MO:-'~1E-"'1"'L

.. L J

Unit Size (MW) 0-

Compelitive Power College

_ 800 1Q1lG

~NERGY

PowerGcn 2005

Structural Steel Framing Model

~NERGY
/.G!iJf'NERGY

Compelilive Power College T PowerGen 2005

Structural Steel Systems

--~=--=

Competitive Power Co,~II",e"g"e:=== _

Structural Steel

PowerGen 2005

30.0

""26.0

".0

22.0

I

20.0

'8,0

'6,0

".0

".

'0.0

••

••

..

,.

•• '00 '00 .00

0

500 GOO 700 800 000 '000

Unll Size (MW)

1.fi8JlNERGY

26
, PowerGen 2005

- Compelitive Power College

SCR Reactor and Ductwork Systems

o ~ERGY

Competitive Power College

Constl\Jcl1on Productivity Rates

Case Study A~lysls

PowerGen 2005

j- ~01. 1- l);""~"d ,r

••

"'~ ~fli lI I sea. &'Pe2" S"""' 1ll

.c " -------.: I

l~

•

•

·

- CIlI ClII

o ~NERGY

27
Competitive Power College . PowerGen 2005

O h~'j,.U,T "'!?£librO"If

SeR Reactor. Ductwork & Expansion Joints

m. ,---- ---,

H'iIi

,..

...

•• L _

UnM Size (M'NJ

~NERGY

Competitive Power College

Isolation/Control Damper Systems

PowerGen 2005

~NERGY

28
Compelitive Power College

Isolation Dampers

...

..

..

,.

I ..

.. I--

..

,.

,.

..

.. - - .00

-- '00

Unit SlI:e (MW)

-• PowerGen 2005

,..

_ _ 'lIOO

lU&!NERGY

~. PowerGen 2005

29
COlllpclitive Power College PowerGen 2005

Unit Size (MW)

o

Catalyst

...

...

'u

I

...

u

u

::[- - .~

--

"...

7lMl _ _ ._

Competitive Power College

Catalyst Cleaning Systems

PowerGen 2005

lGYENERGY

30
Competitive Power College

Catalyst Cleaning Systems

PO\vcrGen 2005

..

••

..

'.' I'.'

,.

••

••

..

..

••

0

11,1;\1

>00 lOCI 4Ol\ 500 _ 700 _ _ ,_

Unit Size (MWI

~ERGY

Compelitive Power College

Ammonia Systems

PowerGen 2005

~NERGY

31
Competitive Power College - PowerGen 2005

n., ".,"

.. f ..

"

..

..

..

"

"

"

"

0

O fl.lbroclPQ..•..Iff to', 1110"'1> ":r"

Ammonia Storage & Injecllon Systems

2IIlI 300 .... 500 _1'DO ICIlI _._

Unn Size (M'W)

lfXlENERGY

Competitive Power College

Dilution/Seal Air Systems

PowcrGcn 2005

·

•·

lG.".iENERGY

32
Competitive Power College

Dilution f Seal Air System

,-- PowcrGen 2005

••

,.

•••

(

,.

..•

"

..

..

.. UnitSil.. (MIN)

~NERGY

Competi!i 5 PowerGen 2005 ve P~o~w:e~r~C~o~I~le~g~e::::=:- ...

O~J6-.:~~E Electrical I InslUments & Controls

'"

o

11.0

'0.0

•••

••

,.

..

..

••

...

..

- - Ill~h

"<>lWl

•

200 100 000 NO _ 700 .., _ ._

Unit SIz. (MW)

~NERGY

33
Compelitive Power College

Total SCR System

(Average Unit Cost)

i PowenJen2005

.. =..

•so.o

I

,so.o

'40,0

'~o.o

100.0

10,0

60.0

...

~o.o

..

0

--

Unit Size (MW)

Competilive Power College

POlenUII Addilional Capital

CO,1 MQdllle,,'ons

PowerGen 2005

1. ABS Air Heater Baskets and Cleaning Systems

2. Economizer Bypass System

3. Boiler Surlace Modifications

4. Ash Collection System ~dilications

5. RetroliUNew 10 Fans & Drives

6. Balance of Plant Modifications

~NERGY

34