St. Johns River Power Park St. Johns River Power Park

2 x 670 MW SCR 2 x 670 MW SCR

Designed to Ensure Fuel Flexibility Designed to Ensure Fuel Flexibility

Gerald Smith – SJRPP – Project Manager

Robert Branning – Tackticks – Project Engin

MEGA Symposium – Baltimore, MD

August 26, 2008
Contributing Authors

• Gerald Smith - SJRPP • Robert Branning – Tackticks, LLC. • John Cochran – CERAM Environmental• Diane Fischer – Black & Veatch• Kathryn Robinson – Black & Veatch• Noel Rosha – CERAM Environmental • Volker Rummenhohl – Tackticks, LLC.
Presentation Agenda

• Project Overview• Fuels – Challenges• Operating Challenges • Catalyst Selection • CoPilot

® Catalyst Demo 

Test Results

• Balance of Plant Concerns
Project Overview

• Two Units – Each 670 MW (gross)• Two 3+1 SCR Reactor Boxes per Unit (14 x 6 Fra• Fuels – Domestic Coal / Colombian Coal / Petcok• High Flue Gas Temperatures – 750 to 800° F• Catalyst Procurement Including Co-Pilot® Catalys• LPA Capture – Aerodynamic and Screen Remova• SO3 Control System (Ammonia) Unit Load Vs. Econ Outlet 

400450500550600650700750800850900

0 100 200 300 400 

Gross Generator Load

Economizer Outlet Temp, F
Fuels – Challenges

Effects on SCR Design, Catalyst Performa

and Catalyst Life
Fuels – Challenges and Risks

Fuel (Blend Portion)

Challenges Risks

Domestic Coal(35 to 100%)

 High Arsenic (up to 30 ppm) Low Calcium Oxide (down to 

0.5%)

 Rapid Cataly

Colombian Coal(35 to 100%)

 High Silica in Fly Ash (up to 

62%)

 Catalyst and 

Erosion

Petroleum Coke(0 to 30%)

 High Sulfur (up to 6.94%) High Vanadium (>2,000 ppm) High Loss on Ignition (LOI)

 Min Operatin Increasing S Increased Fi

Limited Experience With Petcoke 

Blends in SCR Applications
Direct Bunkering of Fuels

• Fuels Fired Separately• Design Considered Flue Gas “Channeling”• Possibility for Targeted Affects CL Burners

7 Rows

D

EC

F

Coal

Petcoke

Coal

Boiler

Gas From

Boiler SCR 

Reactor
Reactor Construction - July 11, 2
Site Construction - Fans
Site Construction – LPA Screens
Site Construction – Catalyst Installat
Operating Challenges
Operating Challenges

• Plant Characterization Testing

• Full Load and Low Load Operation• Mill Configuration• Fuel Combinations

• Ductwork / Reactor Design• Control of SO

3 Emissions

• Control of LPA Carryover into SCR• Maintain Plant Reliability
Catalyst Design, Selection a

CoPilot

® Test Results

Ensuring Performance and Reliability 

Despite the Challenges
Catalyst Characterization Testing and Sel

• Predominant Objectives for Catalyst Procurem

• Initial Low Oxidation Rate • Maintain Low Pluggage• Good Possibilities for Rejuvenation/Rege

• CoPilot

® In-Situ Catalyst Demonstration Tes

• Characterize SO

2 to SO

3 Conversion Rate 

• Characterize Catalyst Activity Changes• Tested Plate and Honeycomb (2 Suppliers

Rotating Basis Between 3 CoPilot

® Test U

• CERAM Homogeneous Honeycomb Catalyst 

Based on Comprehensive Technical and ComEvaluation

• 0.25% Oxidation Rate (3 Layers)• 8.2 mm Pitch/1.0 mm Wall Thickness

CoPilot

® Test Reactor
CoPilot® Door Action

Air Side

Flue Gas Side Allows for Catalyst Tes

Removal Without Uni

Rotated Into

Flue Gas

Rotated Out

of Flue Gas

Rot

Doo
CoPilot® Test Results

Sample

ID

Relative 

Activity, 

K/Ko

Relative

SO2 to SO3

Conversion 

Rate, %

Hours of 

Operation

Fuels Fired (% of 

Colombian Dom 

4083 1.0 1.0 0

1.11 1.0 956 56 16 

4084 1.0 1.0 0

1.10 1.09 2,135 27 43 0.93 1.47 7,280 37 34 

5011 1.0 1.0 0

0.85 1.0 4,535 63 35 

5012 1.0 1.0 0

1.01 1.13 5,145 44 28 
CoPilot® Test Results (cont’d)
CoPilot® Test Results (cont’d)
Catalyst Design Changes 

Following Procurement

• Fuel Changes Occurred Late in the Project

• Petcoke Firing Currently Not Attractive• Catalyst Redesign Required for Current Fuels• Possibility of Petcoke Returning to Fuel Mix

0%

20%40%60%80%

100%120%140%160%

0 5000 10000 

Required Reactor Potential

Operating Hours

SJRPP Reactor Potenti

(18,000 Hour Sizing Bas

With Petroleum Coke (low dWithout Petroleum Coke (h
Revised Catalyst Design

Original Contract Basis (2006) Revised Catalys

Fuel Blend Basis 70% Coal/30% Petcoke 100% CoalCatalyst Pitch 8.2 mm 8.2 mmCatalyst Volume 770 m3 770 m3

Catalyst Deactivation Basis Low Deactivation

(K/Ko=0.88) due to 30% petcoke blend

Medium-High A(K/Ko=0.65) duarsenic/low calc

Catalyst Wall Thickness 1.0 mm 1.0 mmInitial Oxidation Rate 0.25% (Ammonia Off/800 F)

with 3 catalyst layers installed

2.0% (Ammonia 3 catalyst layers 

Guarantee NO

x Outlet 0.06 lb/MBtu

(85% NO

x reduction)

0.06 lb/MBtu(85% NO

x reduc

Guarantee Life 18,000 hours 18,000 hours
Balance of Plant Concerns

Maintaining Plant Operational Excelle

Throughout the Project
Balance of Plant Concerns

• Limestone Addition System

• Increases calcium content in fly ash – mitigates Ars

poisoning effects on catalyst

• Limestone metered and deposited onto coal convey

whenever domestic coal is transferred

• SO

3 Control System

• Injection of ammonia downstream of air heater 

• Upgrade of existing system
Balance of Plant Concerns (con

• Large Particle Ash (LPA) Capture

• Aerodynamic baffles at economizer outlet• LPA screen upstream of SCR inlet

• Air Heater Modifications

• ABS resistant design• Multi-media cleaners on hot and cold end

• Fan Modifications

• New ID Fans• Upgrade of FD and PA Fans
Summary
Summary

• SCR Design Can be Targ

Maintain Fuel Flexibility

• Careful Design, Coordina

Team Support are Essent

• Plant Reliability Can Be 

Despite Design Challeng