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CURRENT STATUS OF SCR IN JAPAN

by: Yasuyuki Nakabayashi and Rikiya Abe

Research and Engineering office, Thermal Power Department

Electric Power Development Co., Ltd.

Tokyo, Japan 100

ABSTRACT

Selective Catalytic Reduction of NOx is widely applied to utility and

industrial boilers in Japan. Among utility boilers, 99 units of them (approx. 110

million Nm3/h) have been equiP~ed with SCR including 22 units of coal firing

boilers (approx. 20 l1\illion Nm /h). Among industrial boilers, 31 units of them

(approx. 3.3 million Nm3/h) have also been applied with SCR (as of April 1986).

SCR installation started in 1977 for oil and gas and in 1979 for coal firing

boilers. These operating experience suggested- us that the cost and performance of

SCR should be discussed again, because the catalyst itself (life, volume

requi rement, et c.) had been imp roved rema rkab ly.

This paper will try to describe those facts from the utility standpoint.

1. Introduction

The selective catalytic reduction (SCR) method is one of the methods for NOx

reduction. The method is rather new and expensive, and most American utilities

have shown a hesitation to the employment of the method.

The method, however, has many merits that the equipment is simple, no

byproduct is produced and it is a dry process causing low temperature loss, and

there has been a strong desire for clarifying some of its characteristics

represented by the catalyst life, reduction of equipment cost and solutions to

secondary troubles.

SCRs were installed early in Japan. As of April 1986, the experience in SCR

operation is 6.5 years for coal firing boilers, 8.5 years for oil firing boilers

and 8 years for LNG firing boilers.

At EPDC, SCRs have been used for A and B trains of Takehara No.1 unit (250

MW) and for Takehara No.3 unit (700 MW) among EPOC's 11 coal fired thermal power

units, and they are operating since June 1981 and March 1983, respectively (that

is, they are operating for the last 5 years and 3 years, respectively).

25-1

IPHAB005183
What we found about the catalyst from these experiences are described below.

<Catalyst life>

The definition of catalyst life is rather difficult. We therefore studied the

period during which the SCR is operated without any additions or replacements to

the initially loaded catalyst. Although there are some exceptions, it can be said

that SCRs have been operated for more than 3 years for coal firing boilers, more

than 4 to 7 years for oil firing boilers and more than 6 years for LNG firing

boilers without any additions or replacements. These values are much larger than

the value of 1 to 2 years which has conventionary been thought to be life of

catalyst. In addition. these values are different from the so-called mean life of

catalyst either. and the mean life would be much longer.

According to the experience at EPOC, it is known for the train A of Takehara

No.1 unit that the mean life of its catalyst (coal firing low dust. system) is at

least more than 4 years.

<Catalyst cost>

The method of cost calculation employed in Japan is different from that used

in the U. S •• the method of EPRI (CS-3603 Project 1256-7 Final Report October 1984

uSCR for coal fired power plants: feasibility and economics"*I) is used as the

base.

For the case of 80% denitrification on inlet NOx of 500 ppm. the EPRI

calculation results in 11.7 mills/kWh for low sulfur coal and 8.8 mills/kWh for

high sulfur coal. the EPOC calculation. on the other hand. results in 5.9

mills/kWh for low sulfur coal and 4.9 mills/kWh for high sulfur coal. which are

about one-half of those of EPRI.

This is a result of simple calculation where [POC used the catalyst life of 4

years while EPRI used the catalyst life of 1 year.

<Catalyst performance>

According to the development in the method of catalyst production. the pitch

of honeycomb catalyst reduced from 10 mm to about 6 mm, and the effective catalytic

area per unit volume (AP value) is much greater now. Therefore. the app'arent

catalyst requirement in volume has been reduced to about two-thirds.

The cost has also become lower correspondingly. and it is 5.2 mills/kWh for

low su 1fu r coa 1•

In addition. we used to have problems of A/H troubles which came from ammonium

bisulfate caused by slip NH3 and 503. but such troubles as A/H clogging are fewer

now due to the recent progress in the development of low 502 oxidation rate

catalysts.

2. SCR App1i cat ions

2.1 Application to Utilities

All SCRs used at utilities in Japan are listed in Table 1. As of April 1986.

22 SCRs for coal firing boilers. 55 SCRs for oil firing boilers and 13 SCRs for LNG

firing boilers are operating. It is considered that the reliability of SCR is

demonstrated by the use of so many SCRs at Japanese utilities.

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IPHAB005184
2.2 Japanese SCR Manufacturers

Mitsubishi Heavy Industries (MHI), Hitachi, Ltd. (HTC) (representing Babcock.

Hitachi (BHK)), Ishikawajima Harima Heavy Industries (IHI), Kawasaki Heavy

Industries (KHI) and Hitachi Zosen (HZC) are the five Japanese manufacturers of

SCRs for utilities.

Among other manufacturers, KHI may be known in the U. S. as it supplied SCRs

to the Arapahoe Test Site of [PRI, Southern California Edison and City of San Diego

in addit i on to cont ri but i ng information to previ ous EPRI report IOSCR for coa 1 fi red

power plants: feasibility and economics."*l

Table 2 shows the supply of SCRs to Japanese utilities, and Figure 1 shows the

shares for coal firing boilers and those for all types of utility boilers.

However, these shares do not represent the qual ity of the SCR because it is

common that the boiler manufacturer receives an order of SCR since it 'is considered

as a part of the boi ler.

3. Catalyst Life

3.1 First Replacement or Addition

It is very difficult to define the life of catalyst. If more catalyst than

needed is charged initially. no replacement will be needed for a very long time.

We should therefore look at the trend of deterioration in catalyst activity instead

of the concept of life. This point will further be discussed later.

A rough rreasure we applied to consider the life of catalyst is to look at the

period between the initial charge of catalyst and the subsequent catalyst

replacement or addition.

Figures 2 to 4 show the starting time of operation and time of catalyst replacement or addition for all SCRs operating in Japan as relations between time

on the abscissa and individual units on the ordinate. For each unit. the X-mark at

the left end of the horizontal solid line corresponds to the starting time of SCR

operation, and the length of the solid line corresponds to the period during which

the SCR was operated without catalyst replacement or addition.

The right X-mark on the solid line indicates the time of catalyst replacement

or addition and a dotted line follows the solid line after the X-mark.

X-marks on dotted line indicate that the catalyst was replaced or added at

such points.

Solid lines up to April 1986 indicate that no catalyst replacement or addition

took place for the unit.

It can roughly be said from these figures that SCRs for coal firing boilers

are operated for 2 to 3 years. those for oil-firing boilers are operated for 4 to 7

years, and those for LNG firing boilers are operated for IOOre than 6 years without

catalyst replacement or addition although there are some exceptions.

The catalyst life is 100M! than expected considering the manufacturers'

guarantee period of 1 year at that time.

In Japan. it is an obligation to carry out a periodic inspection almost every

year, and catalyst replacement or addition is carried out also during such

25-3

IPHAB005185
I

inspection if necessary. If there were no such restriction, the catalyst could be

used much longer.

For the cases of coal firing boilers, the catalyst of first full capacity high

dust SCR unit was replaced after about 2.5 years, but the high dust catalyst had

been improved since then for longer life. In addition, the first full capacity low

dust SCR units are the two units for the A and B trains of Takehara No.1 unit.

The catalyst of these units have been replaced or added for vari ous test purposes,

and it may be appropriate not to include these units in the statistics.

When these cases are excluded, SCRs for coal firing boilers are operated with

the first catalyst for more than 3 years.

3.2 Concept of Mean Catalyst Life

In considering the concept of mean catalyst life. it is necessary to

understand the catalyst activity. overall activity of multi-layer catalyst. actual

trend of activity deterioration and the method of catalyst replacement.

<Catalyst activity>

As shown in Figure 5. the denitrification efficiency is expressed by the

following formula. when the NH3/NOx molar ratio is 1 and the reaction is a linear

reaction of NOx concentration:

II = 1 - e-let

where.

II denitrification efficiency

k catalyst activity

t reaction time

<Overall activity of multi-layer catalyst>

(1)

As shown in Figure 6. the overall activity of multi-layer catalyst is

equivalent to the sum of catalyst activities of component layers. and expressed by

the following formula:

K = leI + k2 + ••••• + len (2)

where.

K: overall activity of n-1ayer catalyst

kl.K2.···.kn: catalyst activity of individual layers

When the catalyst consists of some catalyst layers of low activity and new

catalyst layers, the overall denitrification efficiency can exceed a target value

so far as the overall catalyst activity is greater than the design value.

<Actual trend of activity deterioration>

Figure 7 shows the trend of activity deterioration observed at Takehara No. lA

and 3. We could not obtain data on other power plants, but the trend can be

similar.

<Method of catalyst replacement and addition>

To maintain an overall performance of catalyst layers is to maintain the

overall activity above a certain level. With notion in mind. a variety of methods

25-4

IPHAB005186
for catalyst replacement and addition are considerable. For the purpose of

discussion here, we consider two cases shown in Figure 8.

It is assumed that the amount of catalyst of which overall activity would drop

to a target value in one year is charged in four layers. Case 1 is a method where

all catalyst is replaced every year, and Case 2 is a method where another layer is

added after one year. Figure 8 indicates that the annual catalyst consumption is 4

x V for Case I, and 1 x V for Case 2. From the concept of mean catalyst life, the

life for Case" 2 is four years if the life for Case 1 is one year.

The catalyst activity has been measured up to only five years. The life at

sixth and subsequent years is therefore an estimation, but the mean life can be

extended IllJch longer by employing a more intricate replacement rrethod.

In addition, the rrean life can be made longer by reducing the amount of annual

replacement by increasing the number of catalyst layers.

<Mean catalyst life>

The concept of mean catalyst life becomes extremely difficult to grasp formulti-layer catalyst. It may be better therefore to consider the catalyst as a

simple reagent, and think about its rrean annual consumption in a certain period.

For this purpose, however, it is necessary to acquire data on the trend in

activity deterioration for a much longer term. We do not have such data at

present, and the rrean life of four years obtained for Case 2 is used for

calculation of economy in this paper.

4. Economy of SCR

4.1 Econo~ of SCR in the U. S.

As discussed in Section 1 Introduction, the lyvelized cost for 30 years

reduces to about one half based on the EPRIreport* when the mean life is change

from one year to four years.

According to the report, the SCR cost as of December 1982 is as shown in

Figure 9.

Among these, the case of inlet NOx of 500 ppm (3~ 02 dry) and denitrification

efficiency of 80~ is 'a1so shown in Figure 9 for the case where the catalyst cost

was reduced to one quarter.

For consideration of economy, other factors such as reduction of catalyst

volume due to greater AP value (see <Catalyst performance> in Section 1

Introduction) and re-examination of the contingency factor due to increase of

commercial applications, but it is found that the economy of SCR have greatly

improved even when these factors are ignored.

5. Catalyst Performance

5.1 Performance Improvement by Change in Shape

The standard external dimensions of honeycomb type catalyst is 150W x 150l x

500H or x 1000H. The number of cells has increased along with the improvement in

the manufacturing method. The cell configuration was 13 x 13 cells at first, but

it has been improving to 15x15, 17x17, 20x20 and 21x21 cells. It is said that sorre

manufacturers are developing a cell configuration of 35 x 35 cells.

25-5

IPHAB005187
It can be thought that the denitrification reaction is proportional to the

area to which the flue gas makes contact with the catalyst in the direction of

flow, and the area divided by the apparent volume becomes an important factor.

This value if called the AP value.

AP = 4 x P x n2 x H

2. x 2. x H

2. = np + (n+1)t

.. n(p+t)

Thus.

AP .. 4P

(p+t)2

In Figure 10. AP is expressed as follows:

(1)

(2)

(3)

The AP value of each catalyst is shown in Table 3. If the performance of

catalyst itself remains unchanged, the (apparent) required volume of catalyst

changes when the number of cells is increased as also shown in Table 3.

That is, the requi red volume of 2lx.21-cell catalyst can only be 62% of that of

13x13-cell catalyst.

This fact not only allows to reduce the cost of catalyst itself but also those

for reactors and other related devices.

Catalyst of finer cells may be more vulnerable to such problems as clogging

and pressure loss, but EPOC replaced all pipe-type catalyst of Takehara No. 18 1n

November 1985 with 21x21-cell honeycomb catalyst and the SCR unit is operating in

good condition since then.

5.2 Problem of A/H Clogging

The slip NH3 is limited to 5 ppm or below at almost all plants for the purpose

of avoiding the increase of differential pressure in A/H by acid ammonium sulfate.

At the same time, improvement of catalyst material is also going on to reduce

the oxidation rate of S02.

Figure 11 shows the correlation between the slip NH3 and frequency of A/H

washing observed at the 1atest low dust coal fired thermal power SCR (Takehara No.

3: 700 MW). The fuel coal mainly used at the power plant is low sulfur imported

coal with a sulfur content of 0.6 to 0.8%. (S03 is 2 to 5 ppm.)

The abscissa represents the A/H washing interval (in months) and the ordinate

represents the value of slip NH3.

It is clear that the A/H washing interval gets longer when slip NH3 is lower.

6. Conclusions

As discussed above, the results of long-term SCR operation indicate

unexpectedly long life, low cost and high performance.

EPDC intends to continue every effort for reduction of NOx.

25-6

IPHAB005188
Figure1. Share of SCR manufactures for utility

coal firing boilers

-

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KHI

0.5

N

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""- 3 \ I \ /

IHI

MHI I r18

9 """*'i lilY } MHI

41

HTC -\ ) \ Hle

9.5 28.5

,
Figure 2 Operation experience of SCR

applied at all Japanese coal fired boilers (as of Apr., 1986)

I I I I I I SCR operation without

catalyst addition or

replacement (High dust case)

SCR operation without

t) catalyst addition or

replacement (Low du~t ease)

I : I

Demonstration Test )4 • • • • • •• First addition or replacement

of catalyst

I" I I i I H·· • •••

1 i i F~ ···\"··r..t~~r~~ High dust ease: 2.2-3.2 years

Low dust caSfl: 1.] ·5.5 years

Life of catalyst loaded initially

< Referrence >

1. All data are full rapacity.

2. Average catalyst life shall be

different as has been discussed.

unit A

unitB

....... ... -:)( .. unite

..... ... ... ()( .. ,~ I IIC'.~ •••

e I *, ...

N

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ex:>

Ii--

I ,

Year of operation "'U

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a

1978

4

1979

4

1980

4

198]

4

1982

4

1983

4

1984

4

1985

4

1986

4

,
< Referrcnce >

.....

t

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Figure 3 Operation experience of SCR

applied at all Japanese oil fired boilers (as ofApr.• 1986)

X''---+--'--I--'--+_':'--+--'-~

x~--!--'---+-"';"'-I

x......;--+-...;...--!----;--I

x-+-'----I

:x-~""";--l

x'

x+--':""--I"';"'''';'-4--':''''--I

:x-+---'--t-.......-+--'----1 x·...-+--'----1-"';'-4--':""--1

.....:...- .-~-+--"---1f-~ Lire of c:al.alysL loaded

~_+--1 initially are in a seL of 2.2 La

t----:_-+_-:-_+--I 8.

5 yenrs. ,.i.-

.....:...-

-'--- ~_-+---11. 1\11 units are Cull SCR ..i..-

1,...--:-_-+_-;-._+--lc:npac:iLy except one daLum ..i..-

>oj--.;.---1f--l as is indicaLc:d above. ..i..-

,....._-+---1 2.l\verage c:aLalysllife sh:1l1 J...-

--;-.-+-......:.--+-1 be differenl as has been..i..-

~_-!---;_-+-Idiscussed. ,.i.-

-i--

-'---

IIniL II

uniL ij

uniLe

This dal.., is one "-

quarLer SCR capac:ity.

••••,••••••••;•••••••)4:•••

:" _':'--+--';"'--+--";~-+---";~-+--' ...

>+-~-!--~+oo": 00 '

-+---+---1-----1

:I---:---+--:---!----,--+-----I .......

,........--+----'~+__:__+-,... 00"'"

x· •.••

x--

firsL addition or

replaccment of

cal.alysl

sen opcraLitlll

\Yithnlll cal..,lysl

addition or

rc:pl:lccl1lcnl

1977

4

1978

4

1979

4

1980

-I

1981

4

1932

1\

1983

4

1984

4

1985

4

1986

4

YC:lr of op<lratiull

25-9

IPHAB005191
I I I I I I

Figu re 4 Operation experience of SCR

applied at all Japanese LNG fired boilers (as of Apr., 1986)

SCR operation without

catalyst addition or

replacement

)C • • • • • • • First addition or replacement

ofcatalyst

, I I I ii' I I j Ik· .

N

l.1'1

I

-

o )I~ I I I i I I; I IC- • !... . .

;-

unit A

unitB

unitC

Life ofcatalyst loaded initia lIy

may be more than 5.8 years.

< Rererrence >

1. Average catalyst life sh<lll he

different as has been di!lcll~sed.

1978

4

1979

4

1980

4

1981

4

1982

4

1983

4

1984

4

1985

4

1986

4

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Year or operation

,
* About 11 =1 - e-kt

+ [NOx] in

IZZZZ!,

[NOx] out

When the NH3/NOx molar ratio is 1, the reaction is a

linear reaction of concentration:

d[NOx] = -k [NOx] dt

NOx concentration

catalyst activity

: reaction time

where,

[NOx] :

k

t

Integrating the equation:

[NOx] = Ae-kt

11 = [NOx] in - [NOx] out = A - Ae-kt = 1 _. e-kt

[NOx] in A

Thus, 1 - e-kt

Figure 5. Catalyst activity and DeNOx

efficiency

25-11

IPHAB005193
Catalyst

Layer 1

Catalyst

Layer 2

Catalyst

Layer n

+No ·.......

• • • • • • · .

+N1

· . • • • •••••••• • • • • •

t N2

·

·

· ·

• ..• ...• .

• ..• • • • •

+Nn

Vol. Reaction Catalyst DeNOx

Time Activity efficiency

V t k1 111

V t k2 112

·

·

·

·

·

· V t kn 11n

Overall V

Ni: NOx concentration

t K

<Overall Activity> <Each Activity>

Nn 1 -111 = N1 1-11=- = e-k1t - No No

N1 N2 Nn 1 -112 = N2

=-x-x···x = e-k2t - No N1 Nn~ N1

· = (1-111) X (1-112) X ••• x (1-11n) ·

·

· = e-(k1+k2+ ... +kn)t ·

· Nn = e-knt

=e-Kt 1 -11n = Nn-1

Then K = k1 + k2 + ... + kn

Figure 6. Overall activity in case of

multiple layer

25-12

IPHAB005194
'. -.,.. ~. ,...,.".. ' ....-..-...--.-......-._.".'. - _,-- _- ,.,-_.-. ,

I 0.85

-0

-

-

.-

>.-

0

« N

Q)

U1 > I .- -

W

Q)

a:

0.8 J0.6 J0.41-

0.2 J-

•

88

No. 1A unit

No.3 unit

J

• 0.82

Aug. 1986

• 0.79 0.761 w=~~~:~ 3°1c - Nov. 1986 ofyear

o

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3

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Figure 7.

Operating Time (year),'

Deterioration of relative activity of catalyst

(Takehara No.1 A and 3)
»

<Replacing Method>

Initial charge of catalyst

Number of layers

1-year requirement

4 or 5

(Case 1)

Initial Replace

char~

l.a! r-T++

1st Layer 1.0 ........~~~~6IlIiOA_

2nd Layer 1.0 ~~~~~__

3rd Layer 1.0 .........~~~~~_

4th Layer

(year)

(Case 2)

20 V =4 V/year 5 years

(Mean life: 1 year)

K =3.52

5V 5 years = 1 V/year

. (Mean life: 4.0 years)

K = 3.83

Additional

charge

Initial

charge

Additional t1.0

Layer

1st Layer

2nd Layer 1.0 ~~""""""'~~ _

3rd Layer 1.0 ~~~...-.....: ~_

4th Layer ~~~~.,.,.,..,..

Figure 8. Catalyst life v.s. replacing

method

25-14

IPHAB005196
15 CATALYST 15 ...

12.5 (4 YR LIFE) · .. IC/l · .

0ol: ...

o~ 10 0::':

w- NC/l _-I I-~

7.5 -1-1 C/lW

w- >!:

>:E -1-1

W

5 <ta: -I

· .. ~>

o=.

2.5 . ·.. 2.5 ... . ·.. ·.. ·.. ·.. ·.. ·.. ·.. ·.. ·.. ·.. ·.. ·.. ·.. ·.. ·.. ... ·.. ·.. ·.. ·.. ·.. ·.. ·.. ·.. CAPITAL

NOx · . · . ·.. ·.. · . CHARGES REMOVAL 60 80 90 60 80 90 60 80 90

, ¥ I , ¥ I , Y I

% 200 500 800 INLETNOx

CONC. (PPM)

A. Low Sulfur Coal Application Total Levelized Cost Components

CAPITAL

CHARGES

15

12.5

MISC.

10 POWER &

AMMONIA

7.5

CATALYST

5 REPLACE·

MENT

·.. ·.. ·.. ·..

80 90 • I

800

CATALYST

(4 VR LIFE)

· . ·.. ·.. ··. ·.. ·.. ·.. ·.. ·.. ··. ·.. ·.. ·.. ·.. ·.. ··. · . ·.. ·.. 80 90 60 80 90 60

• I , Y I ,

200 500

2.5

15

NOx 60

REMOVAL ,"--_---...__-J

%

INLET NOx

CONC.(PPM)

t; 12.5

O.c .

~~ -10

wNC/)

~~ 7.5

>:E

W

-I 5

B. High Sulfur Coal Application Total Levelized Cost Components

(EPRI CS-3603 Project 1256-7 Final Report October 1984

"Selective Catalytic Reduction for Coal-fired Power Plant:

Feasibility and Economics")

Figure 9. seR economics based on

4 year's life of catalyst

25-15

IPHAB005197
=

CAPITAL

CHARGES

7.5

CATALYST

5 REPLACE·

MENT

80 90

¥ I

1--.--I"!.-.~.-2.5 ·.. .., ·.. .., ·., .. ,

800

60

"

1---

en w

>!!::

...1...1

<a:

~>

u=..

·., .. , ·., .. , ·., .. , ·.. .., ·.. ·.. ·.. ·.. ·.. · .

2.5

NOx

REMOVAL 60 80 90 60 80 90 .."---.....- __' "'""---.....---'

% 200 500

INLETNOx

CONC. (PPM)

15

12.5

en

OJ::

UJ 10 elll:

~Cii _...J

w-

...J...J 7.5

>== w

...I 5

CAPITAL

CHARGES

·.. ·.. ·.. ·..

L.-....J---f"'2.5 ·.. ·.. ·.. ·..

(/)w ~-­

>~...1...1

<a::

~>O=..

• 80 90I \0..."- 60__..... 80 90'

500 800

60

·.. · .. ·..

"

·., .. ' ·., .. , ·., .. ,

.. low Sulfur Coal Application Totallevelized Cost Components

15

12.5 __-S-~ MISC.

10 POWER &

AMMONIA

7.5

CATALYST

5 REPLACE·

MENT

NOx 60 80 90 REMOVAL","~ .....__~I

% 200 INLETNOx

CONC. (PPM)

A.

15

12.5

en

OJ::

UJ

elll: w.... Nfl) _...I

...1...1

w-

>== W

...I 5

8. High Sulfur Coal Application Totallevelized Cost Components

(EPRI CS-3603 Project 1256-7 Final Report October 1984

"Selective Catalytic Reduction for Coal-fired Power Plant:

Feasibility and Economics")

Figure 9. seR economics based on

4 year's life of catalyst

25-16

IPHAB005198
1

i

,

,

Catalyst surface area

Catalyst outward volume

p: pitch

t: wall thickness

n: number of cells

Left drawing shows

n x n cells honeycomb .

type catalyst

4 x p x n2 x H (m2)

! x! x H (m3)

AP =4 x Px n

2

x H

l xl x H

Figure 10. AP value and catalyst

configuration

25-17

IPHAB005199
12 ..

-en

J:

-C

o 10-

:5

--

aJ

:> 8~ ...

Q)

-

c

.-

C) 6

c

.-J:

o

aJ

3: 4~

J:

<-

.........

........

IIInll"111

111111111111

I

Control

value

(5 ppm)

I

11111/"11/11 """1/

• •

I I

Takehara

, No.3 unit

...

2 4 6

Leak NH3 (ppm, 02 6% dry)

• • Primary A/H

(Primary air heating area: 10,000 m2)

111111111111111111 Secondary A/H

(Secondary air heating area: 50,000 m2)

Figure 11. Interval of scheduled A/H

water washing v.s. slip NH3

25-18

IPHAB005200
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. H.,.· .....' .__ ~. _

Table 1-ill list of DeNOx Facilities for Utility Boiler in Japan (As of 1986,4)

Commi- Treated CommissUnit Output ssioning DeNOx Treated Gas frotal Manu- DeNOx ioning Date No. Company PIS No. (MW) Fuel Dote Facility Vol. (m"N/h) Gos factuerer Emi- of DeNOx (Plan- Rotio deney Facility ning) (%)

1 Hokkaido Tomatou- 1 350 Coal 10/80 5CR 280,000 25 HTC 80 10/80

Alsuma (Plate)

2 Touhoku Sendai 2 175 Coal 11160 SCR(Plate) 549,000 100 HTC 60 5183

3 Touhoku Sendai 3 175 Coal 6162 SCR (Plate) 549,000 100 HTC 60 2183

4 Tohoku Higashi- 2 600 LNG 6183 SCR 1,700,000 100 IHI 62 6183

NiiCata (Honeycomb)

!5 Tohoku Hig8lhi- 3-1- 109012 LNG 10/85 5CR 100 MHI 80 12184

Niigat. 3-3 Combined (Honeycomb) 7,700,00012

6 Tohoku Higashi- 3-4- 109012 LNG 10/85 SCR 100 MHI 80 10/85

Niigata 3-6 Combined (Honeycomb) 7,700,000/2

7 Tokyo Yokohama 1 175 Crude, Heavy 8162 SCR (Plate) 531,000 100 HTC 4181

Oil =-30

LNG

8 Tokyo Yokohama 3 175 Crude, Heavy 4163 SCR (Plate) 100 HTC 3/85

Oil 531,000 :0030

LNG

9 Tokyo Ohi 2 350 Oil 2172 SCR 1,020,000 700 IHI =-30 4/81

(Honeycomb)

10 Tokyo Yokosuka I 265 COM 10/60 SCR 875,/)00 100 MHI 70 2185 , HeavyOil (Honeycomb) ,

11 Tokyo Yokoauka 2 265 COM 9/62 SCR 875,000 100 MHI 70 5/85

He.vyOil (Honeycomb)

12 Tokyo Yokosuka 4 350 Crude. 7/64 SCR 1,076,000 100 MHI =-10 8181

Heavy Oil (Honeycomb)

Reference; Facility ofThennal Power Plants in Japan- Engineering Dept, The Federation ofElectric Power Companies

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Table 1-0 List of DeNOx Facilities for Utility Boiler in Japan (As of 1986,4)

Commi- Treated CommissUnit Output ssioning DeNOx Treated Gas !fotal Manu- DeNOx ioning Date

No. Company PIS No. (MW) Fuel Date Facility Vol. (m'N/h) Gas factuerer Effii- oCDtNOx (Plan· Ratio ciency Facility ning) (%)

13 Tokyo Futtsu 1·1-1·7 1000 LNG 12185- SCR 8,000,000 100 HZC 80 12185-

11/86 (Honeycomb) (11186)

14 Tokyo Fultsu 2-1-2·7 1000 LNG (2188)- SCR 8,000,000 100 HZC SO (2188)-

(11188) (Honeycomb) (ll/8S)

15 Tokyo Higashi. 1 1000 LNG (9/87) SCR 2,770,000 100 HTC SO (9/87)

Ohgishima

16 Tokyo Higashi. 2 1000 LNG (9/89) SCR 2,770,000 100 . SO (9/89)

Ohgishima

17 Chubu Shin-Nagoya 2 220 Heavy Oil 2160 SCR 670,000 100 MHI 33 4/81

(Honeycomb)

18 Chubu Shin-Nagoya 3 220 Heavy Oil 3/61 SCR 650,000 100 MHI 33 9/80

(Honeycomb)

19 Chubu Shin-Nagoya 5 220 Heavy Oil 1/64 SCR 640,000 100 MHI 33 9/81

(Honeycomb)

20 Chubu Shin-:-Iagoya 6 220 Heavy Oil 7/64 SCR 640,000 100 MHI 29 5/81

<Honeycomb)

21 Chubu Chita 1 375 Crude, Heavy 2/66 SCR 1,100,000 100 MIH 48 12182

Oil Oloneycombl

LNG

22 Chubu Chitll 2 375 Crude, 1/67 NCR 1,036,1100 100 MHI 40 1m

Henvy Oil

LNG ,,

23 Chubu Chita 4 700 Crude, 3174 SCR 1,960,000 100 MHI 80 3i80

Heavy Oil (Honeycomb)

LNG

24 Chubu Chito 5 700 LNG 3178 SCH (Pellet! 1,910,000 100 HTC 80 3178

25 Chubu Chilo 6 700 L:'-IG 4178 SCI{ (Pellet! 1,910,000 100 IITC 80 4178

Helerence : l"acllitv 0 Thermal t'ower t'lants In Jaoan· J:o;nl!lneennl! Ueot. The l"ederatlOn 01 ~Iectrlc t'ower Comosnles

t,.,.."
,

Table 1-@) list of DeNOx Facilities for Utility Boiler in Japan (As of 1986,4}

p

Comm;· Treated CommissUnit Output ssioning DeNOx Treated Gas frotal Manu· DeNOx ioning Date No. Company PIS No. (MW) Fuel Date Facility Vol. (m'N/h) Gas factuerer Emi· of DeNOx (Plan. Ratio dency

ning) ('l.) Facility

26 Chubu Nishi·Nagoya 3 375 Crude, Heavy 7n2 SCR(Ptate) 1,000,000 100 HTC 80 12181

Oil

27 Chubu Nishi·Nagoya 4 375 Crude, Heavy 9n2 SCR (Plate) 1,000,000 100 HTC 80 3/8t

Oil

28 Chubu Nishi.Nagoya 5 500 Crude, Heavy 10no4 SCR 1,360,000 100 MHI 70 (10/86)

011 (Honeycomb)

29 Chubu Nishi·Nagoya 6 500 Crude, Heavy 4n5 SCR 1,340.000 100 IHI 80 7/80

Oil (Honeycomb)

30 Chubu Atsumi 3 700 Crude, Heavy 5/81 SCR 1,900,000 100 MHI 80 5/81

Oil (Honeycomb)

31 Chubu Atsumi 4 700 Crude, Heavy 6181 SCR 1.900,000 100 MHI 80 6181

Oil (Honeycomb)

32 Chubu Chita·Daini 1 700 LNG 9/83 SCR 1,910,000 100 HTC 80 9/83

(Pellet)

33 Chubu Chita.Daini " 2 700 LNG 11/83 SCR 1,910,000 100 IHI 80 11/83

(Pellet)

34 Chubu Yokkaichi 4-1- 560 LNG (7/88) SCR 4,300,000 100 Toshiba 80 (7/88)

4-5 LPG (Honeycomb)

311 Chubu OW8l1·Mil.a 3 1100 Crude, (3/87) SCR (Plate) 1,370,000 100 HTC 80 (3/87)

Heavy Oil

36 Hokuriku Toyama· 2 500 Crude, 11/81 SCR 1,350,000 100 1111 80 11/81

Shinkou Heavy Oil (Honeycomb)

37 Kansai Sakai·Kou 1 250 Crude, 12164 SCR 800,000 100 MHI 75 9/80

Heavy Oil (Honeycomb)

LNG

38 Kansai Sakai-Kou 2 250 Crude, 1lI65 SCR 800,000 100 MHI 75 1/82

Heavy Oil (Honeycomb) , LNG

Kelerence ; l'"aclIIty 0 Thermal Power Plants In Japan· EnJ;tJneennlt Uept, The l'"edera Ion or t.lectflc .t'ower I.,;om • "..

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Table 1-@ list of DeNOx Facilities for Utility Boiler in Japan (As of 1986,41

t",.-,

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Commi- Treated CommissUnit Output slioning DeNOlit Treated Gas trotsI Manu- DeNOx ioningDate No. Company PIS No. (MW) Fuel Date Facility Vol-(m"NIh) Gas factuerer Emi- otDeNOx (Plan- Ratio ciency Facility ninc) (~)

39 Kansal Sakai-Kou 4 2~0, Crude, Heavy 3187 SCR 800,000 100 MHI 75 7/81

Oil (Honeycomb)

LNG

40 Kansai Sakai-Kou 5 250 Crude, Heavy 10/67 SCR (Plate) 800,000 100 HTC 75 8180

Oil

LNG

41 Kansal Sakai-Kou 6 260 Crude, Heavy 2168 SCR 800,000 100 MHI 75 7/80

Oil (Honeycomb)

LNG

42 Kansai Sakai-Kou 7 250 Crude, Heavy 10nO SCR 800,000 100 MHI 75 9/81

Oil (Honeycomb)

LNG

43 Kansai Osaka 1 158 Grude. 4159 SCR 530,000 100 MHI 30 10178

Heavy Oil (Honeycomb)

44 Kanlai Osaka 2 156 Grude. 10/59 SCR ~30,OOO 100 MHI 75 8181

Heavy Oil (Honeycomb)

45 Kanlai Osaka 3 156 2160 SCR 530,000 100 MHI 75 9/80

Heavy Oil (Honeycomb)

46 Kansai Osaka 4 156 3160 SCR ~30,OOO 100 MHI 75 6/80

Heavy Oil (Honeycomb)

47 Kanllli Tanogawa 3 156 Crude, Heavy 4/63 SCR 520,000 100 MHI 75 818\

Oil (Honeycomb)

48 Kansai Tanagawa 4 158 Crude, 10/63 SCR 520.000 100 MHI 75 3/81 I

Heavy Oil (Honeycomb) I

49 Kansai Kasullade I 156 Heavy Oil 10/63 SCR 470.000 100 IHI 30 5/80

(Honeycomb)

50 Kanaai Kaaugade 2 156 Heavy Oil 1164 SCR 470,000 100 IHI 30 8/81

(Honeycomb) , 51 Kanaai Tanagawa- 2 600 Crude, 8177 SCR (Plate) 1.520,000 100 HTe 15 8181

Daini Heavy Oil

t<elerence ; l' aelll tv 0 lnermal Power t'lants In JaDan- t;nl1'lneerln . _.... -

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Table 1-rn List of DeNOx Facilities for Utility Boiler in Japan (As of 1986,4)

guep p

Commi- Treated CommissUnit Output Ilioning DeNOx Treated Gas /Total Manu- DeNOx ioning Date No. Company PIS No. (MWI Fuel Date Facility Vol. (m'NIh) Gas factuerer Effii- of DeNOx (Plan· Ratio cieney Facility ning) (%)

52 Kansai Amazaki- 1 156 9/65 SCR(Plate) 470,000 100 HTC 30 Ions

Higashi Heavy Oil

53 Kansai Amazaki· 2 156 10/66 SCR (Plate) 470,000 100 HTC 30 41S0

Higashi Heavy Oil

54 Kansai Amazaki- 1 156 Crude, Heavy 1/63 SCR (Plate) 470,000 100 HTC 30 8ISl

Daisan Oil

55 Kansai Amazaki- 2 156 Crude, Heavy 5/63 SCR (Plate) 470,000 100 HTC 30 7/S0

Daisan Oil

56 Kansai Amazaki- 3 156 Crude, Heavy 9/69 SCR (Plate) 450,000 100 HTC 30 2JSO

Daisan Oil

57 Kansai Kainan 1 450 Crude, Heavy 5nO SCR (Plate) 300,000 25 HTC 75 9/77

Oil

58 Kansai Kainan 3 600 Crude, Heavy 4174 SCR 1,640,000 100 MHI 75 11S2

Oil (Honeycomb)

59 Kansai Kainan 4 600 Crude, Heavy 6n3 SCR(Plate) 1,645,000 100 HTC 75 6ISI

Oil

60 Kansai Himeji- 1 33 Heavy Oil 9/55 SCR 160,000 100 IHI HeavyOil 75 9/82

Daiichi (Honeycomb) Coal so

81 Kansal Himeji. 5 156 Heavy Oil 7/62 SCR 490,000 100 IHI 30 IOnS

Daiichi (Honeycomb)

62 Kansai Himeji. 6 600 Crude, Un3 SCR 1,620,000 100 IHI Crude, Heavy 8181

Daini Heavy Oil (Honeycomb) I Oil 75

LPG , LNG so

63 Kansai Aioi 1 375 Crude, 9/82 SCR 1,060,000 100 IHI 75 9/82

HellYY Oil (Honeycomb)

64 Kansai Aioi 2 375 Crude, ll/S2 SCR 1,060,000 100 !HI 75 11IS2

Heavy Oil (Honeycomb) , Helerence: l"acll11V 01 Tnermal t'ower t'lants an .Japan- EnR:aneerlDR: Uept, The l"ederation 01 ~lectTlC t'ower l om - --

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Table 1-(§) List of DeNOx Facilities for Utility Boiler in Japan (As of 1986,4>'

Commi· Tr.atad Commi.s·

Unit Output .aioning DeNOx TreatedGaa /Total Manu- DeNOx ioning Date

No. Company PIS No. (MW) Fuel Date Facility Vol. (m'NIh) Gas factuerer Emi- orDeNOx (Plan- Ratio ciency Facilily ning) ('II)

65 Kanni Aioi 3 375 Crude, Haavy 1/83 SCR 1,060,000 100 !HI 75 1/83

Oil (Honeycomb)

66 Kanaai Nan-Kou 1 600 LNG (11/89) SCR 1,759,000 100 - 80 (11189)

(Honeycomb)

67 Kanaai Nan·Kou 2 600 LNG (5190) sca 1,759,000 100 - 80 (5/90)

(Honeycomb)

68 Kanaal Nan·Kou 3 600 LNG (11190) SCR 1,759,000 100 - 80 (11/90)

(Honeycomb)

69 Kanaai Gobou I 600 Crude, Heavy 9/8. sca 1,600,000 100 MHI 75 9/84

Oil (Honeycomb)

70 Kansal Gobou 2 600 Crude, Heavy 11/8. sca (Plate) 1.600,000 100 HTC 75 11/84

Oil

71 Kansai Gobou 3 600 Crude, Heavy 3185 SCR 1,600.000 100 MHI 75 3/85

Oil (Honeycomb)

72 Kensai Akou 1 600 Crude, Heavy (8187) SCR 1,600,000 100 MHI 80 (8187)

Oil (Honeycomb)

73 Kansei Akou 2 600 Crude. Heavy (12187) SCR 1,600.000 100 IHI 80 (12187)

Oil (Honeycomb)

74 Kansal Miyazu 1 375 Crude. (8189) SCR 977.400 IDa MHI 80 (8189)

Energy HeavyOil (Honeycomb) I

Lebo.tory

75 Kansai Miyazu 2 375 Crude. (12189) SCR 986,100 lao KHI 80 (12189)

Energy HeevyOil (Honeycomb)

Lnbortory

76 Cyugoku Mizushime I 125 Cool 11/61 SCR (Plale) 450,000 , 100 HTC 65 7/84

77 Cyugoku Mizushima 2 156 Coal 8163 SCR(Plate) 540,000 100 HTC 65 5/84

Helerence: l'acl1ltv 0 Thermal .t'ower .t'lants In Jacan· .t.mnneerlnl!' Uect. The l'"ederal1on 01 .t.lectrlc .t'ower l,;omcantes

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--.._---------_.

Table 1-0 List of DeNOx Facilities for Utility Boiler in Japan (As of 1986,4)

Commi- Trealed Commisso

Unit Output ssioning DeNOx Trealed Gas Irotal Manu- DeNOx ioning Date No. Company PIS No. (MW) Fuel Date Facility Vol. (mON/h) Gas factuerer Emi- ofDeNOx (Plan- Ratio ciency

ning) (%) Faeility

78 Cyugoku Mizushimll 3 350 Crude, Heavy 2/73 SCR(Plate) 950,000 100 HTC 80 6183

Oil

79 Cyugoku Tamashima 1 350 Crude, Heavy 3171 SCR (Plale) 950,000 100 HTC 80 8183

Oil

80 Cyugoku Iwakuni 2 350 Crude, Heavy 4172 SCR 980,000 100 MHI 80 4181

Oil (Honeycomb)

81 Cyugoku Iwakuni 3 500 Crude, Heavy 9/81 SCR 1,400,000 100 MHI 80 9/81

Oil 3/82 (Honeycomb)

LPG

82 Cyugoku Kudamatsu 2 375 Crude, Heavy 7173 SCR 1,050,000 100 IHI 80 9179

Oil (Honeycomb)

83 Cyugoku Kudamal9u 3 700 Crude, Heavy 9179 SCR 1,900,000 100 IH1 80 9179

Oil (Honeycomb)

84 Cyugoku Shin·Ube 1 75 Coal 8158 SCR 300,000 100 MHI 65 5182

(Honeycomb)

85 Cyugoku Shin-Ube 2 75 Coal 5/59 SCR 300,000 100 MHI 65 3182

(Honeycomb)

86 Cyugoku Shin·Ube 3 156 Coal 6162 SCR 580,000 100 MBI 65 2182

(Honeycomb)

87 Cyugoku Shin-Onoda 1 500 Coal 4/86 SCR 1,600,000 100 IH[ 80 4/86

<Honeycomb)

88 Cyugoku Shin-Dnoda 2 500 Coal (2187) SCR 1,600,000 100 , IHI 80 (2/87)

(fIoneycombl I

89 Cyugoku Shimonoaeki I 175 Coal 3/67 SCR 550,000 100 MHI 50 3/81

(Honeycombl

90 Shikoku Saijo 1 156 Coal 11/65 SCR 550,000 100 MIH 65 7/83

(lfoneycomb) ,

Reference; Facility ofThermal Power Plants in Japan- Engineering Dept, The Federation ofElectric Power Companies

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Table 1-00 List of DeNOx Facilities for Utility Boiler in Japan (As of 1986,4)

-

Commi. Treated CommissUnit Output ..ionin, DeNOx Treated Gas rrotal Manu- DeNOx ioning Date No. Company PIS No. (MW) Fuel Date Facility Vol. (m'NIh) Gas factuerer Effii· of DeNOx (Plan· Ratio ciency Facility ning) (,,)

91 Shikoku Saijo 2 2110 Coal 1/84 SCR 800,000 100 IHI 611 1/84

(Honeycomb)

92 Kyuellu Shin·Kokura 1 1118 LNG 10161 SCR 442,000 100 MHI SO 7/S2

(Honeycomb)

93 Kyulhu Shin·Kokura 2 1116 LNG 11162 SCR 484,000 100 KHI 80 4/83

(Honeycomb)

94 Kyulhu Shin.Kokur~ 3 600 LNG 9nS SCR (Pellet) 1,690,000 100 MHI SO 9nS

96 Kyulhu Shin·Kokura 4 800 LNG 8179 SCR (Pellet) 1,890,000 100 MHI SO 6179

98 Kyushu Shin.Kokura 5 600 LNG 7/83 SCR 1.820,000 100 MHI SO 7/S3

97 Kyu.hu Minato 1 156 Coal 9/60 SCR 516,000 100 MHI 110 4/83

(Honeycomb)

9S Kyulhu Matluura I 700 Coal (7189) SCR 2,207,000 100 - SO (7/89)

(Honeycomb)

99 Kyulhu Shin·Ohita 1·1- 690 LNG (7/91) SCR (Plate) 5,400,000 100 - SO (7/911

1·6

100 EPDC Takehara I 2110 Coal 7/67 SCR Sll1,OOIl 100 HTC SO 10/82

(Plate,Pipe) KHI

101 EPDC Takehara 3 700 Coal 3183 SCR (Plate) 2,320,000 100 HTC SO 3183

I

102 EPDC Matluura 1 1000 Coal (7190) SCR 3,029,000 100 - SO (7/90)

103 Sakata Sakata 1 350 Coal 9/84 SCR 1,140,000 100 MHI 28 9/84

(Honeycomb)

Kelerence : jl'aCl11ty 0 Thennal Yower .t'lants In Japan- t;nlOneermlllJep •The jl·ed.eratlon ol./!;lectrlC Yower (.;ompanles

,

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Table 1-(2) list of DeNOx Facilities for Utility Boiler in Japan (As of 1986,4}

Commi- Treated CommissUnit Output Isioning DeNOx Trealed Gas /Total Manu- DeNOx ioning Date No. Company PIS Fuel Date Gas Emi· No. lMW) (Plan- Facility Vol. (m'N/h) Ratio factuerer ciency of DeNOx

ning) (%) Facility

104 Sakall1 Sakata 2 350 Heavy Oil 10n8 SCR 1,140,000 100 MHI 28 ~/A

(Honeycomb)

105 Joban Nakoso 8 600 Coal 9/83 SCR 1,800,000 100 MHI 60 9/83

Heavy Oil (Honeycomb)

106 Joban Nako80 9 600 Coal 12/83 SCR 1,800,000 100 IHI 60 12/83

Heavy Oil (Honeycomb)

107 Toyama Toyama 1 250 Coal 9nl SCR(Plate) 690,000 100 HTC 60 11/84

Sinkou

108 Toyama Toyama 2 250 Coal 6/72 SCR(Plale) 690,000 100 UTC 60 12/84

Sinkou

109 Tobata Tobata 4 375 NllturalOaa 3/78 SCR 1,563,800 MHI 60 6/81

from Coke, (Honeycomb)

Blast and

Converting

Furnace

Reference; Facility ofThermal Power Plants in Japan- Engineering Dept, The Federation ofElectric Power Companies ,

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Table 2 SCR manufacturers for utility boilers in Japan

(units: as of April 1986)

MHi HTC IHI KHI HZC Total

coal 9 9.5 3 0.5 0 22

oil 26 16 13 0 0 55

LNG 6 3 2 1 1 13

,

Total 41 28.5 18 1.5 1 90 ,

....---'---}
..._ _~.~,,...., -.<1-'", "I'~;"'''''''''''''''' ..,, , 'I"-".~"'•.• " •. __, ••_ ••_.__•

Table 3 Required catalyst amount in relation

with configuration improvement

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1.0

13 x 13 cells 15 x 15 17 x 17 20x20 21 x 21

p(mm) 9.8 8.0 7.4 6.0 6.0

t(mm) 1.8 1.8 1.4 1.4 1.0

AP(m2/m3) 291 321 382 427 470

catalyst ,

Amount 100 % 90% 76% 68 6

/0 620/0

Required (Base)

(% ) ,