# • November 18,2009. 

## By: Craig Sharp and Bryan Pourchot HALDOR TOPSDE (]j

# Table 

# of contents • Trends in SCR DeNOx applications

- Coal fired power plants

- Biomass

- Gas turbines 

## • New catalyst developments

- Cerafil TopKat

- Monolith catalysts

HALDOR TOPSCE 

### III

# Coal-fired power plants • Biomass firing and co-firing

- SCR 

### catalyst deactivation. II 

### Lower temperature operation

- Minimum temperature issues II 

### SCR in low'-rank coal fired units

- Catalyst deactivation II 

### Catalyst regeneration

HALDOR TOPSDE rJj

# DONG Energy, Studstrup Power Station • 2 

# x 350 MWe 

### • 10% straw on energy basis has been co-fired since 2002 and 2005 in the two units

HALDOR TOPSOE [I]

## Coal/straw co-firing at Studstup Power Station
- Plugging**du~e** 

## to incomplete burn-out ofthe straw

___l!Ii!IiBiillllBifB!Jj

Ref: Dong Energy, Expperts 2008 Brussels HALDOR TOPSDE [Ij

# Biomass 

# and SCR 

# deactivation III Evaporation of potassium in the furnace

- Deactivation rate: Different furnace types have different catalyst deactivation rates III Nucleation offine sub-micron potassium aerosols III Deposition of aerosols on catalysts surface III Diffusion into catalyst by surface diffusion III Reaction with active site 4,600 service hours at Nassjo Power Plant (accelerated test) Quantitative chemical analysis shows 7,000 ppmw potassium

HALDOR TOPSDE 

### L!:l

# Bench scale experiments with furnace Injection of potassium salt solutions

_____**.wr£illg!E\~!;'/"·i,;** III Continuous flow of aerosol through the catalyst is required for deactivation III Impregnation experiments show the same effect of sulphate and chloride III Difference between sulphate and chloride deactivation rates indicates an effect of surface diffusion mobility or aerosol deposition rate KCI aerosols
!3D

20 & 2nd! iKeI exp,osetl, acWr'j --e- 2nd! Kel ex(XJsetl, &he Borbed NHlli D--of---r---.----...----r---r---,----,.---,---,,.---i. I) 2'(10 4'11(1 ·IltOO 800 1000 I:hcposlJ!re time llhj Deactivation 50%/1 GOGh Zheng et. alAppliedcatalysis B: Environmental K2SO4 aerosols 1{!1J) .

!l0

10 i I (I' 500' 10(1) 1M!!ll'**~MO** :2500 ;'!I)I){J! E:lCpMum, time ·th]' Deactivation 300/0/1000h HALDOR TOPSDE l[]

# KCI powder deactivation experiments

____**.il1Si~)]jf** 

### • Commercial grade KCI placed on catalyst

- Almost no deactivation of center catalyst

- No deactivation ofdownstream catalyst 

### • Fly ash recovered from full scale reactor placed on catalyst

- No deactivation observed
350°C, 2500 hours HALDOR TOPSDE L!j Zheng et. 81Appliedcatalysis B: Environmental

# LowerTemperature SCR Operation Improved activity at lowertemperature Ko Type factor as a function of NOx level at various temperature, ANF = 1.0 2.5

2

600 550 500 450 400 350 D**~-...I---J..-.L.--4---l..---L--...JI...--..J---i-...L--..l.---L-......J--+--L--.l...-..J..-....,L...-.....j---.L-....I.---L-..L.--l--.J--L.--L--L-....j**

300 Gas Temperature,OF HALDOR TOPSCE (1j

# Undisclosed Site 16 MW CHP II Grate fired boiler II Fuel: Wood chips II SCR installed in 2008 III Low dust, vertical up 

### &down flow II NOx Inlet, O.118lbs/mmBtu II NOx reduction, 64% II SCR temperature 340 - 360°F III On line catalyst cleaning

- reverse flow II Catalyst deactivation is less than expected II SCR inlet SOl3 < 0.5 Rpm (calc. ASS dew point> 450°F HALOOR TOPSCE []j

# Lower Temperature Operation • ASS inhibition at typical coal-fired conditions

HALDOR TOPSDE []j

# Tail End SCR • 2 x 260 MWe, 2 x 300 MWe PC boilers, PRS fired • Low Dust, Tail End SCR • Vertical down flow • NOx Inlet, 

### 100 ppm II 

### NOx reduction, 

### 570/0 II 

### SCR temperature 490°F II 

### Service Life - 

### 32,000 Hours • SCR inlet 

## 803 < 

### 1 ppm (calc. ASS dew point greater than operating temperature) • Install Date! - 

### 2011 HALDOR TOPSDE []]

# Simple Cycle Gas Turbines

__**~l!1~!!ir01!0;;"** 

## • High temperature SCR 

## (900 - 1,1 OO°F) • Frequent 

## start ups • Fast temperature 

## ramps

HALDOR TOPSDE (]j

# High Temperature SCR Operation

__....**_.M~t;}~l'···''''''**


### o**StrongE~r** 

### NH3 

### absorption o Lower NH3 

### oxidation rate o Higher DeNOx activity 100.0

80.0 

# ,..----- ?.,.----.... )( 0 60.0 

### z ." J: 40.0 a. ...... 

# - - c 20.0 0.0 

### . £ I I 0.5 'I 1.5 2 

### ANF -.-20ppn NOr-IHI @01OD6-2-i2)

___OOppm NO); IHI @0'1006-2-2) ;-lJppm NOxIHl (DNXJJD) -.-C5ppm rKix IHI I]HH<JOCl) 

## Improved 

## activity at highertemperature DNX-()29HiTe

HALDOR TOPSDE 

### IIi

# New DNX-029HiTe Catalyst Vra Power Plant III 

### Power Output - 5 Mwe III 

### Flue gas flow - 150,000 Ibs/hr Flue gas temp. - 1,050 deg. F III 

### NOx inlet - 110 ppm III 

### DNX-029 Installed - June 2008 Performance: III 

### Daily Start ups III 

### Over4,000 operating. hours III 

### NOx Reduction - 80% III 

### Zero Catalyst Deactivation**HALDO~** TOPSOE []j

# DNX-029HiTe Catalyst Field Experience

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### H3 inje

### etediNOX inlet - 

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### 40**HALDO~** TOPSDE I]j

# TopKat technology

__**"_ii_I~&7JIft'** 

### CLEAREDGE" Filtration

0.3mm Ceramic film ! 10-20 mm wall ceramic fiber matrix Dust layer with catalyst particles \ I I . '.:n

. : .. ).-**.~** \ 

## • Ceramic filter Tolerates high temperature and temperature excursions Acid gas resistant Impregnated for catalytic activity**HALOO~** TOPSOE !]j

# Equipment train options 

# for dust, SOx and NOx ESP based TopKat based Fabric filter based HALDOR TOPSCE []j

# TopKat operation below ASS dew point

__.... i_twA?Y'·········



### 30 ppm 

### 503 1500 ppm NH3 1 I I

## , 1

## , '. 12 ppm NH3 

### \, J \ 1.4 ppm 

### 503,

'... ---- -------------------.0.1 ppm NH3 

# i 225°C 193°C

Catalyst 

# 1 Filter cake 

## +

oppm TASS bulk dew point HALDOR TOPSDE LIj

# TopKat reference list

___IIiIIII.i!Ji£Q •.**,,~'!fJlfii;'Yi·** II 

### References and projects 5 waste incineration plants III Cooperl III Andouillettes Troyes III Addenbrook III Uchiko III Perfect Metal (start up 2009) France France France Japan Romania No. of CTK-3000 filters 672 80 270 (CTK-1000) 540 900



### CLEi\R'EDGEN Filtratlon HALDOR TOPSDE [Jj

# Colombo Barge, Sri Lanka TopKat pilot trial

• 2T 12K50MC-S 18 MW II 

### 250-300°C in stack II 

### 2-2.5% S HFO • 500 ppm S()2 • 5% H2

## 0 

## • 150/0 O2 II 

### 1500 ppm NOx

HALDOR TOPSOE []j

# SCR catalyst developments

____**i~~&g;''';** 

## • Biomass optimised catalyst

- Competitive sites for poison binding

- Catalyst system with inhibition of poison diffusion 

## • Lowertemperature operation catalyst

- Improved activitywith lower deactivation 

## • High temperature gas turbine catalyst

- Improved activity and durability at high temperatures 

## • New SCR DeNOx technologies

- Cerafil TopKat

HALDOR TOPSCE L!j

# Questions? Thankyou

HALDOR TOPSCE []j