# Typical Installation Tim elines for NO x 

# Emissions Control Technologies

on Industrial Sources

Institute of Clean Air Companies 1730 M Street NW Suite 206 Washington, DC 20036

- 5603 Telephone 202.457.0911 Fax 202.331.1388

David C. Foer ter, Executive Director Chad S. Whiteman, Deputy Director

December 4 , 2006Institute of Clean Air Companies

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About the Institute of Clean Air Companies

The Institute of Clean Air Companies (ICAC) is the national trade association of companies that supply air pollution control an d monitoring technologies for stationary sources who provide solutions for a broad range of industrial applications as well as electric power plants. ICAC represents more than ninety of the leading manufacturers who provid e emissions control solutions for

affected industries as well as employment opportunities across the U.S. ICAC gives the air pollution control and monitoring industry a responsible and responsive presence in Washington, DC and throughout the country, which works constructively with gover nment, business, public

, and p rivate groups to ensure that the air pollution control industry and its products are properly represented and understood.

Introduction

The following document provides information concerning the time needed for the install ation of emissions control technologies for industrial sources. The document focuses on the deployment time of NO x controls that are applied to various industrial categories including the following : low NO x burners, selective non

- catalytic reduction, sel

ective catalytic reduction, and non

selective catalytic reduction . The information below can be used as a general guide for the typical time required to complete a typical NO x control project from the initial bidding period through the start

- up of the ins talled control technology. The level of retrofit difficulty and site specific conditions may increase or decrease the time required for the deployment of the control technology.

There are several points in the NO x control technology deployment process wh ere the end user dictates the amount of time consumed. For example, c ontrol technology manufacturers rely on the end user during the bid evaluation, project negotiation, review of engineering drawings, review of flow modeling studies (if applicable), sche duling the outage (if applicable), and compliance testing

steps

. For these steps , the end user is in control of the time required to complete each step as opposed to the emissions control manufacturer. For example, the timing of the initial bid evaluatio n and negotiation may vary depending on the amount of resources the end user has available to review and proceed with the decision making process or the amount of time prior the end user has prior to meeting a compliance deadline

. The following deployment timelines have assumed that the affected source has decided to move forward with the installation of the control technology and is working with emissions control manufacturer s to move the project forward in a reasonable timeframe.

Low NO

x Burner s and Flue Gas Recirculation

There are a number of types of combustion control technologies that have been applied to industrial sources depending on the application and emissions requirement . The deployment times for two of the combustion control technologie s including low NO x burners (LNB) and LNB in conjunction with

flue gas recircul ation (FGR) are discussed below.

Low NO

x Burners

- For coal

- , oil

- , and gas

- fired boilers , low NO x burners decrease the air introduced into the primary combustion zone thereby creating a fuel

- rich environment and lowerInstitute of Clean Air Companies

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combustion temperatures that work to lower NO x formation. Conventional burner s operate with

excess combustion air when compared to the stoichiometric requirement for complete combustion. When applying low NO x bu rners, t he percentage of excess air is reduced in the primary combustion zone with the remaining air required for complete burnout of combustibles added where the temperature is sufficiently low so that additional NO x formation is minimized. Ultra Low NO x Burners are an advanced generation of low NO x burners that provides additional NO x reductions through improved designs

.

LNB + Flue Gas Recirculation

- Flue gas recirculation reduces NO x emissions by recirculating and mixing 5

- 4 0 percent o f the boiler flu e gas with the combustion air prior to combustion in the main combustion chamber. This process reduces the peak combustion temperature and lowers the percentage of oxygen in the combustion air/flue gas mixture; thus retarding the formation of thermal NO x caused by high flame temperatures. FGR is often used in combination with LNB to reduce NO x emission

s below levels that may be achieved by using LNB alone

. FGR has been applied to natural gas, kerosene, distillate oil , and coal

- fired boilers.

The deploym ent time for

r etrofitting an existing boiler with LNB or ultra

- LNB is relatively short due to the simplicity of the technology and the small number of burners on most industrial boiler s

. The vast majority of oil

- and gas

- fired package boilers used for var ious industrial applications have just one or two burners making the retrofits less intensive. A complete LNB system retrofit typically includes the following major components: windbox, burner(s), and burner management system. LNB manufacturers typicall y design their systems to keep the retrofit cost to a minimum by replacing only critical firing components, while keeping most of the burner system intact. For example, a LNB manufacturer may design their LNB system to adapt to the existing windbox geomet ry, backup fuel firing system, and ignition equipment. By minimizing the changes of equipment, LNB manufacturers minimize the amount of time required for the retrofit.

Retrofit ting an existing industrial b oiler with flue gas recirculation involves inst allation of a system to extract the flue gas f rom the boiler unit, ductwork, and fan

. The deployment of a complete LNB + FGR system will include: windbox, burner(s), burner management system, potentially larger fan for FGR, and ductwork for FGR. A fly a sh control device is necessary for coal

- fired applications in order to clean the flue gas of particulate matter prior to recirculation of the gases back into the boiler

. Retrofitting existing oil

- and gas

- fired boiler s with flue gas recirculation involves all of the same components except for the fly ash collecting device.

For a complete system, the t ypical deployment of LNB or LNB + FGR takes between 24

- 32 weeks (6

–8 months) on a typical industrial boiler covering th e bid evaluation through the start

up of the technology. The deployment schedule for complete LNB or LNB + FGR technology

on a typical industrial boiler can be divid ed into the following timeframes :

• 4

- 8 weeks

–bid evaluation and negotiation

• 4

- 6 weeks

- engineering and completion of eng ineering drawings

• 2 weeks

–drawing review and approval from end user

• 10

- 12 weeks

–fabrication of equipment and shipping to end user siteInstitute of Clean Air Companies

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• 2

- 3 weeks

–installation at end user site (Most of the components of the technology can be installed while the boiler is operating. The boiler may be required to shut

- down for 1

- 2 days for a simple burner change

- out or as much as seven days for a complete system installation.)

• 1 week

–commissioning and start

- up of technology

Variations in the schedule may occur d ue to site specific conditions that may increase or decrease the typical deployment time. The typical deployment time is short for systems that can use the existing burner management system, windbox, and other components and replace just the burner(s). For these applications , the deployment schedule may be as little as 12

- 16 weeks if only the burner

( s ) are being replaced.

S elective Non

- Catalytic Reductio n

Selective non

- catalytic reduction (SNCR) is a chemical process for removing NO x from flue gas. In the SNCR process, a reagent, typically urea or anhydrous gaseous ammonia is injected into the hot flue gas and reacts with the NO x , converting it to nitrogen gas and water vapor. The chemical reaction for this technology i s driven by high temperatures , ty pically from 1,600

– 2,100 ° F, normally found in combustion sources. SNCR is “selective” in that the reagent reacts primarily with NO x .

SNCR may be combined with low NO x burners (LNB), over

- fire air (OFA), neural network s , ri ch reagent injection (RRI), s elective catalytic reduction (SCR) systems

, or with gas rebur n technologies to provide additional emissions reductions

. C ombined SNCR/SCR system s are finding new applications allowing higher overall NO x reduction than SNCR alone and lower ammonia slip.

T he principal components of the SNCR system are the reagent storage and injection system, which includes tanks, pumps, injectors, distribution modules, and associated controls. The combustion unit acts as the reactor chamber simplifying the SNCR process

. The reagent is generally injected within the boiler superheater and reheater radiant and convective regions, where the combustion gas temperature is at the required temperature range. The number of injection ports and location is determined by flue gas fl ow and temperature profiles.

SNCR is a proven and reliable technology. SNCR was firs t applied commercially in 1974 and has been installed on approximately 400 applications worldwide. Applications include utility boilers and a broad range of i ndustrial applications including installations on the following : wood

- fired boilers, coal

- fired boilers, co

- generation boilers, pulp and paper boilers , steel industry furnaces , refinery process units, process heaters, cement kilns, municipal waste combustors, glas s melting furnaces, hazardous waste incinerators, and other combustion sources

. U rea

- based SNCR has been applied commercially to sour ces ranging in size from a 60 mm Btu/hr (gross heat input) paper mill sludge incinerator to a 640 MWe pulverized coal

- fuele d, wall

- fired electric utility boiler.

Given the simplicity of the SNCR system components, installation of SNCR is relatively easy and can be done in a relatively short period of time

. It typically takes between 42

- 5 1 weeks (10

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13 months) to complete t he SNCR project going from the bi d evaluation through start

- up. Under special circumstances and during periods of lower SNCR manufacturer activity, SNCR installati ons are typically completed in eight (8) months. A typical timeline for the completion of a n SNCR projection starting from the commercial request for quote (RFQ) to the compliance testing is given in Table 1 below . Certain steps in the SNCR installation process have prerequisite

steps while others may occur simultaneously. Below is a brief des cription of some of the aspects of the SNCR project timing:

1) Initial Stages of Planning and Development a) Bid E valuation

– After the end user submits the request for quote (RFQ), the APC manufacturer will take typically take between 2

- 4 weeks to submit t he proposal

. The APC manufacturer relies on the end user to provide the appropriate information concerning the application in order to provide the design proposal. Some end users have in

- house engineering resources that are make this process run more eff iciently

. b) Initial Engineering

–Once the bid has been accepted, the initial engineering for the site will typically take between 1

- 4 weeks and is typically completed 4

- 8 weeks from the commercial RFQ date . The initial engineering will include things like the design of any concrete work for the reagent storage tanks and distribution system, placement of control systems, siting power delivery, etc. c) Modeling & Engineering Drawings

–Computational fluid dynamic (CFD) modeling and engineering drawings are typic ally completed 18 weeks after the RFQ. The CFD modeling will help determine the number and location of the reagent injection ports that will be incorporated into engineering drawings. Initial engineering drawings are produced by the APC manufacturer and submitted to the end user for comment. The APC manufacturer addresses the comments and prepares the general arrangement drawings. 2) P rocurement

, Fabrication, Shipping

–The procurement, fabrication , and shipment of the various components of the SNCR sys tem will typically be completed by the 34 th week from the RFQ. It typically take s between 16

- 20 weeks for this phase of the project

. Some of the typical components that will need to be procured for the SNCR system include: urea solutionizing equipment ( if applicable), reagent storage tank, injection lances, reagent control system, reagent pumps, reagent distribution piping, etc. Once the items have been procured, some of the components will need to be assembled prior to shipment including: reagent distr ibution models and piping , pump skid, process control skid, etc. The equipment is usually small enough to be shipped by truck upon assembly. Th e timing for shipment depends on

the relative distance from the fabrication shop to the end user’s site. 3) Equipm ent Installation

– The equipment installation will typically be completed 42 weeks from the RFQ. Once the original engineering is complete at the end user site and the fabricated components arrive on

- site, the equipment installa tion will take between 8

- 12 weeks not including the outage . Most of the equipment installation will be completed while the unit is operating. An outage of betw een 7

- 14 days may be required to install the reagent injection ports and lances in the combustion chamber. Usually, the w ork is done within an outage taken for other scheduled reasons. The amount of time taken for injection port installation will vary depending on the type of SNCR installation and the availability of existing ports on the combustion unit . If ports o n the c ombustion unit are already in place

, then the time needed to install the injection lances will be at a minimum

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4) Equipment Start

- Up

– Once all of the equipment has been installed, there will be a period of
start

- up, optimization, and compliance testing tha t will typically be completed some time between the 42 nd

and 51 st week from the RFQ. It typically takes 2

- 4 weeks to complete the
start

- up after the installation; 2

- 4 weeks for the optimization; and approximately 3 weeks for the compliance testing.

SN CR Project Activity Responsibility Weeks from Commercial RFQ Date

RFQ Issued Customer 0
APC Manufacturer Issues Proposal Customer 2

- 4
Bid Evaluation and Negotiation Customer 4

- 8
Receipt of Purchase Order Customer 8
Begin Equipment Design APC Manufactu rer 9
Begin CFD/CKM Modeling a APC Manufacturer 9
Submit P&ID Drawings b APC Manufacturer 12

Customer P&ID Drawing Review and Comment Customer 14
Submit General Arrangement Drawings APC Manufacturer 16
Submit Modeling Report APC Manufacturer 16

Custome r Comments Received Customer 18
Start Equipment Fabrication APC Manufacturer 18
Equipment Shipment APC Manufacturer 34

Installation Complete (Outage work for injection port installation) TBD 8 to 12 weeks (Non

- Outage) 1 to 2 weeks (Outage) c Startup Co mplete APC Manufacturer 42 to 46 weeks
Optimization

Complete APC Manufacturer 44 to 48 weeks Compliance Testing

Complete Customer 47 to 51 weeks

a

- Computational fluid dynamic modeling provides in

- depth analysis of a complex fluid flow, including detai led flow characteristics (velocity, pressure, turbulence, temperature, species concentration) for process optimization

. b

–P&ID drawings are process flow and instrument drawings that show process flow paths for liquids, solids, and electrical systems.

c

- The injection port installation is done within an outage taken for other scheduled reasons and typically takes from one to two weeks. The injection port installation may be performed at the same time as other equipment fabrication or during another peri od of the SNCR project and may not add more time to the overall length of the SNCR project.Institute of Clean Air Companies

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Selective Catalytic Reduction

Selective c atalytic r eduction (SCR) technology has been practiced worldwide for over 50 years with hundreds of successful applicatio ns in a broad field of industrial applications. Selective catalytic r eduction technology has been successfully applied to a wide variety of combustion and chemical process operations including : gas turbines, stationary spark ignition engines, stationary compression ignition engines, refinery heaters, packaged boilers, ethylene cracker furnaces, nitric acid plants, catalyst manufacturing processes, nitrogen fixation processes, and solid/liquid or gas waste incineration equipment. The experience with SCR o n industrial applications has been throughout the United States, with high concentrations in California, New Jersey

, and Texas due to their more stringent N O x requirements. SCR has been used by itself and in combination with other technologies, such as SN CR, LNB

, and FGR.

Th e principal of operation for an SCR system is to inject a reducing agent into the hot flue gas upstream of a catalyst. The catalyst accelerates the reaction of the reducing agent with NO x and is used to broaden the range of operatin g conditions, market applications

, and NO x destruction efficiencies achievable. The catalyst promotes the selective reaction of NH 3 with NO x , forming nitrogen and water. Depending on the manufacturer’s system, the catalyst may be a packed bed of pellets, extrudates or other particulate shapes, or as rigid honeycomb or plate type cubes that are assembled to form the catalyst bed. The reducing agent for SCR can be anhydrous ammonia, aqueous ammonia, or urea. Care is taken to inject the amount of reducing agent equal to the amount of N O x in the stream to avoid excess ammonia , or ammonia slip. On most SCR applications, the flue gas temperature for optimum NO x reduction is typically achieved between 500

- 1

, 000 oF. Catalyst designs can be tailored for the app lications specific temperature window. For gas

- fired boiler applications, catalysts have been designed for optimum performance at lower temperatures between 300

- 700 oF.

For smaller application s where the exhaust flow rate is 20,000 SCFM or less, SCR systems are supplied in a ready

- to

- install SCR skid package. SCR skid packages are typically applied on packaged boilers, engines, some chemical processes, etc. In addition , s tandard SCR packaged systems are available for the complete range of firetube a nd watertube boilers as well . The primary components of the SCR system include: ammonia storage and delivery system, ammonia injection grid, and catalyst reactor. The ammonia injection grid and SCR catalyst can often be installed immediately before or i n the stack, ther e by avoiding any modifications to combustion or heat

- recovery equipment or negative effects on other upstream plant operations.

For larger application

s of 20,000 SCFM or greater, designs permit a modular ly construc ted system, providing a high degree of flexibility in the design of the SCR system for the specific application

, particularly for retrofit

applications . This has made the SCR technology a cost

effective retrofit technology for gas

- fired industrial boilers, larger chemical inst allations, distributed generation facilities, and major waste incineration plants.

Installation timing for SCR often depends on the size of the application and will be discussed in terms of those units that have flue gas flowrates less than 20,000 SCFM and those greater than 20,000 SCFM. Since smaller systems are skid mounted and designed for quick installation in the field, the deployment process from bid through startup takes significantly less time than a largerInstitute of Clean Air Companies

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field erected system. The following t able lays out the SCR deployment time from the request for quote issued by the end user to the optimization and compliance testing.

Weeks From Commercial RFQ Date

SCR Project Activity <20,000 SCFM SCR System >20,000 SCFM

SCR System

RFQ Issued 0 0

APC Manufacturer Issues Proposal 1

- 3 2

- 4

Bid Evaluation and Negotiation 2

- 6 4

- 8

Receipt of Purchase Order 6 8

Client Kick Off Meeting 7 9

Customer GA a & P&ID Draw ing Review and Comment 9

- 10 16

- 20

Drawing Review w/Customer 11

- 12 18

- 24

Start Equipment Fabrication 12

- 13 20

- 24

Equipment Shop Tested 22

- 23 36

- 40

Equipment Shipment 23

- 24 38

- 42

Field Installation Complete 26

- 30 44

- 52

Startup Complete 27

- 32 46

- 56

Optimization & Compliance Testing 28

- 36 48

- 58

a GA

–general arrangement drawings are scale d, dimensioned, and annotated to reflect a reasonable layout for the project.

In summary, smaller skid

- mounted SCR systems can be supplied from RFQ to compliance testing in 7

- 9 months or in approximately six (6) months from the purchase order to startup

. Most of this time is spent in engineering design, fabrication, and field installation. Larger SCR systems that are field erected from modular components are typically supplied from RFQ to compliance testing

in 11

- 1 3 months or in 9

- 12 months from the purch ase order to startup.Institute of Clean Air Companies

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Non

- Selective Catalytic Reduction (NSCR)

Stationary NSCR, as with the automobile sector, involves the use of a three

- way catalyst technology to promote the reduction of NO x to nitrogen and water and simultaneous oxidation of CO and HC to carbon dioxide and water. NO x is reduced by the CO and H 2 over the catalyst under slightly rich or stoichiometric conditions to produce CO 2 and water with typical conversion

efficiencies in the range 80

- 9 9 percent achievable together with corres ponding decreases in HC and CO.

Non

- selective catalytic reduction (NSCR) can be applied to various spark ignited internal combustion engines that are rich

- burn, including natural gas

- fueled engines. These types of engines are commonly found in the foll owing applications: gas gathering and storage, gas transmission, power generation, combined heat and power, cogeneration/trigeneration, irrigation, inert gas production, and non

- road mobile machinery. NSCR has been used routinely in the automotive indust

ry to reduce vehicular carbon monoxide, hydrocarbons

, and NO x emissions with over a billion catalyst units equipped to automobiles since the mid

- 1970s. The application of NSCR to stationary gas engines for the control of NO x and CO first became commercial ly available in North America in the late 1980s and have well over 5,000 stationary engine installations in service today.

In addition to catalysts and housings (converters), NSCR retrofits require installation of an oxygen sensor and feedback control ler to maintain an appropriate air

- to

- fuel ratio under variable load conditions. The catalyst applied to NSCR typically contains active metals such as platinum, palladium

, and rhodium and is typically in the form of highly durable metallic monolith elemen ts. NSCR converters are available off

- the

- shelf for very short turn

- around installations. The time required for the deployment of off

- the

- shelf NSCR products is 6 to 8 weeks and for standard product s , 8 to14 weeks with the following steps:

• 2

- 4 weeks

- b id proposal and evaluation

• 4

- 6 weeks

–engineering and shipping

• 1

- 2 weeks

–installation

• 1

- 2 weeks

–start

- upInstitute of Clean Air Companies

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# MEMBERS

Members ADA Environmental Solutions, LLC ALSTOM Power Argillon LLC Babcock & Wilcox Babcock Power Inc. BASF Belco Technologies Corporation Black & Veatch Burns & McDonnell Chemical Lime Company Cormetech, Inc. CRI Catalyst Company CSM Worldwide, Inc. Dürr Environmental

& Energy Systems Epcon Industrial Systems Forney Corporation Fuel Tech GE Energy Services Ha ldor Topsoe, Inc. Hamon Research

- Cottrell, Inc. Hitachi Power Systems America, Ltd. Hitz America Inc. Horiba Instruments, Inc. Johnson Ma tthey Stationary Source Emissions Control Land Instruments International , An AMETECK Co. Marsulex Environmental Technol ogies Mitsubishi Power Systems, Inc. Mobotec USA, Inc. Ohio Lumex Powerspan Corporation Sargent & Lundy, LLC SICK Maihak, Inc. Spectrum Systems, Inc. Stone & Webster Engineering Corporation Süd

- Chemie , Inc. Tekran Instruments Corp. Teledyne Monitor Labs T hermo Electron Corporation Washington Group International, Inc. Wheelabrator Air Pollution Control Worley Parsons Associate Members Advanced Electron Beams Airflow Sciences Corporation Airgas, Inc. Andover Technology Partners Applied Ceramics, Inc. Asp ectrics Avogadro Environmental Corporation Baldwin Environmental, Inc. California Analytical Instruments Carmeuse North America Casey Industrial, Inc. CEM Service Group, Inc. Chemco Systems LP Corning, Incorporated Dekoron / Unitherm , Inc. ECOM America Ltd. Energy Services Consultants Environmental Systems Corporation Evergreen Energy FF E Minerals FlowTack, LLC Graymont Inc. GT&S, Inc. Linde Gas, LLC M&C Products Analysis Technology, Inc. Matheson Trigas, Inc. McIlvaine Company Midwesco Filter Resources, Inc

. Millennium Chemicals , A Lyondell Company NORIT Americas Inc. NWL Transformers Parker Hannifin

, Parflex Division Perma Pure Praxair, Inc. PSP Industries Rauschert Process Technologies, Inc. Restek Corporation RJF Consultants, LLC Scott Specialty Gases, In c. SCR

- Tech Solvay Chemicals, Inc. Spectra Gases, Inc. Structural Steel Services, Inc. Terra Environmental Technologies Testo, Inc. Thermon Manufacturing Co. TLT Babcock Inc. Universal Analyzers, Inc. VIM Technologies, Inc. VIG Industries, Inc. Zachry Cons truction Corporation