Reinhold Environmental Ltd.

____________________________

2009 NOx-Combustion Round

Table & Expo Presentation

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February 9 & 10, 2009, Cleveland, OH
Codan Development LLC

“Pre-SCR SBS Injection at DP&L

Killen & Stuart Stations”

8th Annual NOx /PCUG Conference

February 9-12, 2009Cleveland, Ohio
Codan

Agenda

z SBS InjectionTM Technology Overview

z “Pre-SCR” Injection Concept & Benefitsz Summary of R&D Program Resultsz Pre-SCR Applications at Killen & Stuart

3⁄4System description & configuration3⁄4Performance testing results3⁄4Future operation & testing plans
Codan

SBS Technology Description

z Patented Technology

3⁄4 Owned by Codan Development, commercialized by U

z Reagent Injected via Dual-Fluid Nozzles

3⁄4 Sodium-based solutions of soda ash or sodium sulfit3⁄4 Droplets are flash dried to form a fine particulate

3⁄4 Particulate selectively reacts with SO3

z High SO3 Removal Efficiency

3⁄4 Injection lance & baffle design give full coverage acro3⁄4 Optimum average particle size (5-7μ)

z Product Collected in ESP or Wet Scrubber

3⁄4 Neutral to positive impact on ESP performance3⁄4 99%+ removal efficiencies in wet scrubber

z Simple & Reliable Equipment Operation

3⁄4 Routine preventative maintenance is essential
Codan
Codan

Vertical Injection Lances in SCR Outlet Duct
Codan

Commercial SBS Installations

Utility Plant Location MW Design SO3 Injection Location Reagent Operat

Seaso

FirstEnergy Mansfield 1-3 Shippingport, PA 3x860 80 Air Heater Inlet Sodium Sulfite Year-ro

TVA Widows Creek 7 Stevenson, AL 550 54 Air Heater Inlet Sodium Sulfite Ozon

NIPSCO Bailly 8 Porter, IN 365 59 Air Heater Outlet Sodium Carbonate Ozon

Vectren Culley 3 Newburgh, IN 287 48 SCR Outlet Byproduct SBS Year-roPPL Montour 1-2 Washingtonville, PA 2x765 42 Air Heater Outlet Sodium Carbonate Ozon

Duke Energy Gibson 1-5 E. Mt. Carmel, IN 5x650 110 Air Heater Outlet Sodium Carbonate Ozon

DP&L Killen 2 Manchester, OH 635 34 / 36 Econ Outlet SCR Outlet Sodium Carbonate Year-ro

IP&L Harding St 7 Indianapolis, IN 465 58 SCR Outlet Sodium Carbonate Year-ro

NIPSCO Bailly 7 Porter, IN 180 59 SCR Outlet Sodium Carbonate Year-ro

DP&L Stuart 1-4 Aberdeen, OH 4x620 90 Econ Outlet Sodium Carbonate Year-ro

12,500 MW Installed on 20 Boilers; ~ 3000 MW Planne

12,500 MW Installed on 20 Boilers; ~ 3000 MW Planne

12,500 MW Installed on 20 Boilers; ~ 3000 MW Planne
Codan

Gibson June 2004 – No Treat
Codan

Gibson June 2005 – SBS Injec
Codan

Benefits of SO3 Control

z Opacity Eliminationz Corrosion Reductionz Co-Removal of Hg, HCl & Se with Fly Asz Enhanced Heat Recovery with CO2 Red

z SCR/SNCR Operating Flexibility

3⁄4Enhance NOx removal

3⁄4Extend catalyst life3⁄4Reduce the SCR Minimum Operating Temp
Codan

SBS Injection Locations

SCR Outlet

Air Heater Outlet

ESP Outlet / 

Scrubber Inlet

Economizer 

Outlet / SCR 

Inlet
Codan

Agenda

z SBS InjectionTM Technology Overview

z “Pre-SCR” Injection Concept & Benefitsz Summary of R&D Program Resultsz Pre-SCR Applications at Killen & Stuart

3⁄4System description & configuration3⁄4Performance testing results3⁄4Future operation & testing plans
Codan

“Pre-SCR” Injection Benefits

z Benefit #1 - Increased Residence Time f

Removal

3⁄4Increases SO3 removal3⁄4Provides benefits associated with removing 

upstream of AH if a suitable injection locatioavailable between the SCR & AH

z Benefit #2 - Reduced Minimum Operatin

Temperature (MOT) within the SCR
Codan

Impact of SO3 on the SCR MOT

z SO3 Reacts with NH3 to form ABS

3⁄4NH3 concentrations are high within the SCR 

3⁄4ABS condenses at higher temperatures with

catalyst pores due to capillary condensation

3⁄4Prolonged operation with ABS formation wil

catalyst

3⁄4Catalyst suppliers specify an MOT that avoi

deactivation
Codan

Impact of SO3 on the SCR MOT

z MOT Management Strategies

3⁄4Reduce or terminate ammonia flow3⁄4Raise the SCR temperature with economize

other economizer modifications or duct burn

3⁄4Restrict lower-load operation3⁄4Fire lower-sulfur coals3⁄4“Burn off” condensed ABS3⁄4Remove SO3 upstream of the SCR
Codan

520540560580600620640

0 5 10 15 20 25 3

SO3 Concentration, ppm

Minimum Operating Temperature, °F

Minimum Operating Temperature versu

Composite Range of 

MOT Information 

Provided by Catalyst 

Suppliers
Codan

Example MOT Relationship

510520530540550560570580590600610620

1.0E-10 1.0E-09 

Mole Fraction SO3 x Mole Fraction NH3 

Minimum Operating Temp, °F @ 3 ppm @ 12 p

@ 30 ppm
Codan

Example: MOT-limited NOx Removal vers

0

102030405060708090

100

200 250 300 350 400 450 500 550 600 65

Unit Load, MW

Maximum NO

x Removal, %

1 ppm SO3 w/SBS2 ppm SO3 w/SBS3 ppm SO3 w/SBS5 ppm SO3 w/SBS12 ppm SO317 ppm SO3Target NOx Remo

3 ppm 12 ppm
Codan

MOT Impact on Cycling Unit

Unit Load Profile

0

102030405060708090

100

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 

Percentage Operating Hours Less Than Stated Load

Unit Load (%) 85% NOx Removal 0% NOx 

Removal

85% NOx 

Removal
Codan

Net Impact on NO

x Emissions

$0$2$4$6$8

$10$12

High SO3; 85% Rem Low SO3; 85% Rem Low SO3; 95% 

Annual NOx Emission Value ($M/yr)

650 MW 10,000 Btu/kW-hr75% Cap Factor0.45 lb/MMBtu NOx$2500/ton NOx Value

0.19 

lb/MMBtu

0.075 

lb/MMBtu

0.025 

lb/MMBtu
Codan

Agenda

z SBS InjectionTM Technology Overview

z “Pre-SCR” Injection Concept & Benefitsz Summary of R&D Program Resultsz Pre-SCR Applications at Killen & Stuart

3⁄4System description & configuration3⁄4Performance testing results3⁄4Future operation & testing plans
Codan

“Pre-SCR” Injection Development Iss

z Impacts of Sodium Injection Ahead of th

3⁄4Impact on SCR catalyst performance?3⁄4Requirements to protect catalyst activity?3⁄4Removal of SO3 generated by the SCR?

3⁄4BOP impacts such as changes in mercury o

or chloride removal?
Codan

Pre-SCR Research & Experience to 

z Three-Phase Research Effort

3⁄4Phase I – Short term catalyst exposure3⁄4Phase II – Longer-term exposure (2,000 hou3⁄4Phase III – Pilot testing at the MRC to identi

issues
Codan

“Pre-SCR” Development Program

z Participating Utilities:

3⁄4FirstEnergy3⁄4Ameren3⁄4Dayton Power & Light3⁄4Duke Energy3⁄4Reliant Energy3⁄4Southern Company

z Other Participants:

3⁄4Ceram, Cormetech, FERCo
Codan

“Pre-SCR” Research Conclusion

z No Sodium-Related Impacts

3⁄4 Normal SCR operation (2,000 Hours)3⁄4 Under simulated lay-up conditions

z Minimal Impacts of Ambient Air Exposure

3⁄4 Ambient air temperature heated by 15°F

z Sodium Accumulation Noted on Catalyst Surfa

3⁄4 Critical to evaluate this at full-scale3⁄4 Catalyst protection measures are recommended

z Modest Removal of the SCR-Generated SO3z No Other BOP Impacts were Identified
Codan

Pre-SCR Research & Experience to 

z Commercial Applications at Killen & Stu

3⁄4Killen – Low-dust SCR, two injection locatio3⁄4Stuart – High-dust SCR, injection upstream

z Commercial Application at a Midwest Ut

3⁄4Injection upstream of high-dust SCR3⁄4System currently in startup
Codan

Agenda

z SBS InjectionTM Technology Overview

z “Pre-SCR” Injection Concept & Benefitsz Summary of R&D Program Resultsz Pre-SCR Applications at Killen & Stuart

3⁄4System description & configuration3⁄4Performance testing results3⁄4Future operation & testing plans
Codan

DP&L Killen Unit 2

z Nominal 635 MW z Hot-Side ESPz Low-Dust SCRz Rothmueller APH’sz Chiyoda FGDz Economizer Bypass

3⁄4Bypass flow is limited

z Plant will be Increasing Coal Sulfur Leve
Codan

DP&L Killen Unit 2 – SBS Design

z Minimum Operating Temperature Const

3⁄4NOx reduction limited at all loads

z SBS Injection at Econ Outlet and SCR O

z SBS in Operation through 2008 Ozone S

3⁄4Performance testing conducted in May 20083⁄4Continuous injection at the economizer outle3⁄4Periodic injection at the SCR outlet

z SCR & SBS Systems in Continuous Ope

3⁄4Working through “cold weather” issues
Codan

Injection Location: Economizer O

Economizer 

Economizer 

Outlet

To Hot-Side 

ESP

Injection 
Codan
Codan

Injection Location: SCR Outlet

To Primary Air 

Heater

To Second

Heater

SCR Outlet

Injection Location

SCR Bypass
Codan

Performance Testing - Killen

z Key Results

3⁄4Lower-load boiler SO2 conversion higher tha

expected

3⁄4Up to 75% SO3 removal at SCR inlet (< 3 pp

3⁄4AH inlet SO3 concentrations below 4 ppm

8 Breen probe indicated no condensable compound

8 Continued operation possible with low cold-end te8 Other secondary benefits should be possible
Codan

DP&L Stuart Units 1 - 4

z Four Boilers (Nominal 621 MW Each)z Fuel Sulfur Level will Increasez High-Dust SCR

3⁄4SCR operation impacted by MOT3⁄4Year-round SCR operation 

z Economizer Bypass

3⁄4Reliability is an issue 3⁄4Currently open at all loads3⁄4Effectiveness is uncertain
Codan

DP&L Stuart Units 1 – 4: SBS Des

z Primary Objectives

3⁄4Retain ability to inject ammonia at lower loa3⁄4Allow use of higher-sulfur coal blends

z Inject SBS at Economizer Outlet

3⁄4Treat both boiler- & SCR-generated SO3

z SBS Start-Up Completed on All Four Un

3⁄4Unit 4 operated ~3 weeks in September3⁄4SBS injection on all units in Nov/Dec 20083⁄4Performance enhancement demonstration in 
Codan

Injection Location: Economizer O

SCR Fi

Ammonia Injection GridFlow Straightening Device

SBS Injection Lances

SCR Inlet Flow Straightening Device

Existing Vanes

Economizer Bypass Duct

Economizer Outlet
Codan

Injection Location: Economizer O
Codan

Performance Testing – Stuart

z Key Results

3⁄4Constant percentage SO2 conversion in boil

3⁄490% SO3 removal at SCR inlet

8 SCR inlet SO3 concentrations below 1 ppm

8 Elevated Na:SO3 molar ratio promotes SO3 remov

8 Allows compliance with Consent Decree NOx redu

requirements over normal load range

3⁄4AH inlet SO3 concentrations below 6 ppm

8 Should improve AH performance relative to no SB
Codan

Future Operation & Planned Tes

z Stuart Performance Enhancement Demo

3⁄4Pre-SCR strategy impacts all downstream e3⁄4Numerous operating variables including fuel 

economizer bypass, SBS, Consent Decree, AH outlet temperature & ammonia slip

3⁄4Demonstration objectives:

8 Identify optimum approach for SBS & other equip

8 Demonstrate operating conditions that reduce cos
Codan

Catalyst Protection Issues

z Catalyst Protection Measures Under 

Consideration

z Strategies during Reactor Maintenance

3⁄4 Minimize ambient air intrusion into the reacto3⁄4Provide heating to slightly raise reactor temp

z Strategies for SCR Start-Up

3⁄4Increase the size of dilution air heaters to ma

catalyst temperature above the flue gas watepoint
Codan

Catalyst Protection Issues

z Catalyst Sampling & Testing

3⁄4 Measure catalyst activity & sodium level3⁄4Testing to evaluate impact of exposure to hu3⁄4Results of October catalyst sampling not yet 3⁄4In-situ catalyst activity measurements

z No Current SCR Operating Problems at 

Station
Codan

Summary

z Pre-SCR Experience is being Accumulat

Killen & Stuart through Operation and Te

z SO3 Removals are Sufficient to Meet MO

Objectives

z Potential for Secondary Benefits will be E

3⁄4Initial testing of elevated slip operation at Kil3⁄4Comprehensive demonstration testing at Stu
Codan

Summary

z Catalyst Protection Measures are being 

Developed & Implemented at Both Plant

3⁄4Catalyst testing results will help to quantify lo

catalyst performance and to define outage arequirements

3⁄4No current SCR operating issues

z Pre-SCR Approach Beneficial for Other 

3⁄4Conversion to higher-sulfur coals3⁄4 MOT operating constraints at lower loads3⁄4Year-round operation with more cycling