Implementation of SCR

at

Southern Company

EPRI Second Workshop

for

Selective Catalytic Reduction

April 18-21, 2000

Ed Healy

Darryl Wall

Krista Paseur 
Presentation Outline

Regulated Business 

• Regulatory Drivers 

• Strategy Development 

• SCR Design Philosophy 

• Project Examples 

Implementation of SCR at Southern Company

Non Regulated Business 

•Business Issues and Drivers 

•SCR Design Philosophy 

•Project Examples 
Implementation of SCR at Southern Company

Regulatory Drivers

•Title IV of 1990 Clean Air Act 

 - Acid Rain Program 

•Title I of 1990 Clean Air Act 

 - Old, 1-hour Ozone Standard 

 - Regional NOx SIP Call 

 - New, 8-hour Ozone Standard 

•EPA NSR Lawsuit 
Ozone Non-Attainment Counties

Attala

Clarke

Covington

Forrest

George

Hancock

Harrison Jackson

Jasper

Jefferson

Davis

Jones

Kemper

Lamar

Leake

Madison

Marion

Neshoba

Newton

Pearl River

Perry

Rankin

Simpson

Smith

Stone

Walthall

Wayne

Winston

1-Hour and 8-Hour Potential 8-Hour

Implementation of SCR at Southern Company
Old 1-Hour Ozone Standard 

Potential NOx Compliance Requirements*

Alabama Power 

Georgia Power 

Gulf Power 

Mississippi 

Power 

Arkwright

Wansley Branch

Mitchell

Gadsden

Greene Co.

Barry

Smith

Crist Scholz

Daniel

Watson

McIntosh

Kraft

Savannah 

Electric 

Miller

Gorgas

Gaston

Scherer

Hammond

Bowen

McDonough

Yates

McManus

* Assumed tonnage cap in 2007 based on 0.15 lb/MBtu NOx rate

Implementation of SCR at Southern Company
States Affected by Regional

SIP Call

22 Current States

Possible Additional 

States

Implementation of SCR at Southern Company
Implementation of SCR at Southern Company

Developing a NOx Compliance Strategy

• Develop unit specific conceptual capital / O&M 

cost estimates and performance expectations. 

• Use projected future years’ generation/fuel 

burn to project future NOx emissions 

• Develop a menu of NOx control technologies 

and combinations of technologies for each unit 

• Rank the controls for each unit on a $/ton of 

NOx removed basis 

• Select units and controls based on least $/ton 

basis to achieve required NOx reduction 
Implementation of SCR at Southern Company

SCR Conceptual Capital Cost Estimate

Plant Percent Reduction

SCR Estimate Module Description 90% 85% 80% 75% 70% 65% 60% 55% 50%

 SCR Reactor and NOx Reduction 3,812 3,812 3,327 3,327 3,327 3,327 3,327 3,327 3,327

 SCR Reactor Support Steel 4,758 4,758 4,758 4,758 4,758 4,758 4,758 4,758 4,758

 Elevator 194 194 194 194 194 194 194 194 194

 Catalyst 9,725 8,731 8,116 7,682 7,330 7,032 6,752 6,498 6,254

 Sootblowers for the SCR Reactor 844 844 681 681 681 681 681 681 681

 Economizer Bypass 376 376 376 376 376 376 376 376 376

 Ash Handling 1,854 1,854 1,854 1,854 1,854 1,854 1,854 1,854 1,854

 Ammonia Storage & Dillution 1,207 1,207 1,207 1,207 1,207 1,207 1,207 1,207 1,207

 Ammonia Injection 1,659 1,659 1,492 1,492 1,492 1,492 1,307 1,307 1,307

 Boiler House Modifications 563 563 563 563 563 563 563 563 563

 SCR Ductwork Modifications 3,729 3,729 3,729 3,729 3,729 3,729 3,729 3,729 3,729

 Balanced Draft Conversion --- --- --- --- --- --- --- --- --- 

 Electrostatic Precipitator Modifications 275 275 275 275 275 275 275 275 275

 ID Fan Modifications 518 518 518 518 518 518 518 518 518

 FD an PA Fan Modifications --- --- --- --- --- --- --- --- --- 

 Air Preheater 4,050 4,050 4,050 4,050 4,050 4,050 4,050 4,050 4,050

 Instrumentation & Controls 1,548 1,548 1,548 1,548 1,548 1,548 1,548 1,548 1,548

 Demolition / Relocation 514 514 514 514 514 514 514 514 514

 Training 100 100 100 100 100 100 100 100 100

 Spare Parts 7 5 7 5 7 5 7 5 7 5 7 5 7 5 7 5 7 5

 Asbestos Abatement 440 440 440 440 440 440 440 440 440

 Subtotal Directs 36,241 35,247 33,817 33,383 33,031 32,733 32,268 32,014 31,770

Direct Dollar / KW (Nameplate) 5 2 5 0 4 8 4 8 4 7 4 7 4 6 4 6 4 5

 Indirect Cost 363 353 339 334 331 328 323 321 318

 SCS Engineering 2,591 2,591 2,509 2,509 2,509 2,509 2,491 2,491 2,491

 Field Supervision 363 353 339 334 331 328 323 321 318

 Other Company Labor 363 353 339 334 331 328 323 321 318

 Subtotal 39,921 38,897 37,343 36,894 36,533 36,226 35,728 35,468 35,215

Direct + Indirect Dollar / KW (Nameplate) 5 7 5 6 5 3 5 3 5 2 5 2 5 1 5 1 5 0

 Contingency 7,931 7,923 7,640 7,636 7,634 7,632 7,577 7,576 7,573

 Subtotal 47,852 46,820 44,983 44,530 44,167 43,858 43,305 43,044 42,788

Dollar / KW (Nameplate) w / Contingency 6 8 6 7 6 4 6 4 6 3 6 3 6 2 6 1 6 1
Implementation of SCR at Southern Company

SCR Conceptual O&M Cost Estimate

 First Year O&M Cost (Fixed and Variable) in K$

Inlet NOx

0.50 0.45 0.40 0.38 0.35 0.30 0.25 O&M Equations

NOx Red

90% $2,923 $2,836 $2,749 $2,714 $2,662 $2,574 $2,487 O&M (k$) = 2051 + 1745 x (Inlet NOx)

85% $2,744 $2,661 $2,579 $2,546 $2,497 $2,414 $2,332 O&M (k$) = 1920 + 1647 x (Inlet NOx)

80% $2,597 $2,520 $2,442 $2,411 $2,365 $2,287 $2,210 O&M (k$) = 1823 + 1549 x (Inlet NOx)

75% $2,491 $2,418 $2,346 $2,316 $2,273 $2,200 $2,127 O&M (k$) = 1764 + 1455 x (Inlet NOx)

70% $2,396 $2,329 $2,261 $2,234 $2,193 $2,125 $2,057 O&M (k$) = 1718 + 1357 x (Inlet NOx)

65% $2,308 $2,245 $2,182 $2,157 $2,119 $2,056 $1,993 O&M (k$) = 1678 + 1260 x (Inlet NOx)

60% $2,220 $2,161 $2,103 $2,080 $2,045 $1,987 $1,929 O&M (k$) = 1638 + 1163 x (Inlet NOx)

55% $2,137 $2,084 $2,030 $2,009 $1,977 $1,924 $1,871 O&M (k$) = 1604 + 1065 x (Inlet NOx)

50% $2,057 $2,008 $1,960 $1,940 $1,911 $1,863 $1,814 O&M (k$) = 1571 + 971 x (Inlet NOx)

 Station Serv ice in Killowatts

Inlet NOx

0.5 0.45 0.4 0.38 0.35 0.3 0.25 Station Serv ice Equations

NOx Red

90% 3277 3242 3208 3194 3173 3139 3105 SS (kW) = 2933 + 688 x (Inlet NOx)

85% 3168 3135 3103 3090 3070 3038 3005 SS (kW) = 2843 + 649 x (Inlet NOx)

80% 3092 3061 3030 3018 3000 2969 2939 SS (kW) = 2786 + 611 x (Inlet NOx)

75% 3032 3003 2974 2963 2946 2917 2888 SS (kW) = 2745 + 573 x (Inlet NOx)

70% 2982 2955 2928 2918 2902 2875 2848 SS (kW) = 2714 + 535 x (Inlet NOx)

65% 2934 2909 2885 2875 2860 2835 2810 SS (kW) = 2686 + 497 x (Inlet NOx)

60% 2891 2868 2845 2836 2822 2799 2776 SS (kW) = 2661 + 458 x (Inlet NOx)

55% 2847 2826 2805 2797 2784 2763 2742 SS (kW) = 2637 + 420 x (Inlet NOx)

50% 2803 2784 2765 2758 2746 2727 2708 SS (kW) = 2612 + 382 x (Inlet NOx)
Implementation of SCR at Southern Company

SCR Design Philosophy - New Generation

• Natural Gas (only) Combined Cycle Plants 

• GE Frame 7 Combustion Turbine 

• Year Round SCR Operation (No HRSG Bypass) 

• SCR Designed for Power Augmentation 

• SCR Procured as part of HRSG Suppliers 

Scope 

• SCR Emission Performance 

 - 3.5 ppm NOx 

 - 10 ppm NH3 Slip 

 - 5 year catalyst life 
Implementation of SCR at Southern Company

SCR Design Philosophy - Retrofit

• Large Pulverized Coal-fired Boilers 

• Non Attainment Area Emission Averaging Between 

Plants 

• Ozone Season Operation (full flow bypass) 

• Anhydrous Ammonia Reagent 

• SCR Emission Performance 

 - 85% NOx Reduction 

 - 2 ppm NH3 Slip with NOx and Slip Distribution 

 - 16,000 Hour Catalyst Life 

 - 1% SO2 to SO3 Oxidation (maximum) 

 - Pressure Drop Determined on Plant by Plant 
Implementation of SCR at Southern Company

SCR Design Philosophy - Retrofit 

(continued)

• Use Combination of Cold Flow and CFD Modeling 

• Maximum Leverage Engineering 

• Volume Procurement of SCR Components 

 - Catalyst 

 - Dampers 

 - Sootblowers 

 - Ammonia Storage and Vaporization 

• Maximize Use of Modularized Design & Construction 

• Utilize Combination of Implementation Contracts 

• Maximize Current Planned Outage Schedule 
Implementation of SCR at Southern Company

Regulated Project Example - New Generation

Barry / Daniel Combined Cycle Project 

• 2 x 500 MW Combined Cycle Blocks at Each Site 

• GE Frame 7FA Combustion Turbine 

• Natural Gas (only) Fuel 

• Vogt / Hitachi SCR Furnished with HRSG 

• Hitachi Plate Catalyst 

• Anhydrous Ammonia 

• Commercial Operation - Ozone Season 2000 
Implementation of SCR at Southern Company

Barry Combined Cycle Project

SCR Spool Piece 
Implementation of SCR at Southern Company

Regulated Project Example - Coal Retrofit

Georgia Power Plant Bowen 

• Units 1&2: 756 MW Supercritical T-Fired Boilers 

• Units 3&4: 950 MW Supercritical T-Fired Boilers 

• Central Appalachian Coal (~1% Sulfur, 12% Ash) 

• 85% NOx Removal: 0.45 #/MBTU / 0.07 #/MBTU 

• 2 ppm NH3 Ammonia Slip 

• Southern Company Generation Design 

• Cormetech Catalyst 

• Anhydrous Ammonia 

• Two Construction Outages 

• Commercial Operation - U1/2 Ozone Season 2001 

 - U3/4 Ozone Season 2003 
Implementation of SCR at Southern Company

Plant Bowen Unit 1 SCR Construction

APH Outlet Duct 

ESP Crossover Duct 

Blocking Back of 

Boiler House 
Implementation of SCR at Southern Company

Plant Bowen Unit 1 SCR Construction

Crossover Duct Interference 
Implementation of SCR at Southern Company 

Plant Bowen Unit 1 SCR Construction

Interference Removed 

SOUTHERN A 

COMPANY 

Energy to Serve ~ur World" 
Implementation of SCR at Southern Company 

Plant Bowen Unit 1 SCR Construction

SOUTHERN A 

COMPANY 

Energy to Serve ~ur World" 
Implementation of SCR at Southern Company

Plant Bowen Unit 1 SCR Construction

Water Collecting Excavated Hole 
Implementation of SCR at Southern Company

Plant Bowen Unit 1 SCR Construction

Unit 2 Unit 1
Implementation of SCR at Southern Company

Alabama Power Power Plant Gorgas Unit 10 

• 780 MW Supercritical T-Fired Boilers 

• Alabama Coal (~1.5% Sulfur, 12% Ash) 

• 85% NOx Removal: 0.55 #/MBTU / 0.08 #/MBTU 

• 2 ppm NH3 Ammonia Slip 

• Southern Company Generation Design 

• Cormetech Catalyst 

• Anhydrous Ammonia 

• One Construction Outage Required 

• Commercial Operation - Ozone Season 2002 

Regulated Project Example - Coal Retrofit
Implementation of SCR at Southern Company 

Plant Gorgas Unit 10 SCR Concept

SOUTHERN A 

COMPANY 

Energy to Serve ~ur World" 
Implementation of SCR at Southern Company

Plant Gorgas Unit 10 SCR Fuel Analysis

Comparison of Arsenic and CaO Fuel Content

0.0

100.0

200.0

300.0

400.0

500.0

600.0

0 1 2 3 4 5 6 7

CaO in Ash, % Dry Basis As in Ash, ppm Dry Basis

Plant Bowen

Plant Gorgas
Implementation of SCR at Southern Company

Non-Regulated Business Drivers

• Permitting of New Projects and Additional 

Generating Capacity 

• Local Non-attainment Requirements 

• Local State SIP Requirements 

• NOx Allowance Trading Revenue 

• Offsets for Various Industrial Sources 

• Deregulation and Merchant Plant Dispatch 

Considerations 

• Wide Range and Variety of Spot Market Fuels 

• Satisfy Local Regulatory Requirements 
Implementation of SCR at Southern Company

Non-Regulated Project Example

Southern Energy Canal 

• 2 x 600 MW No. 6 Oil-fired Boilers 

• 80% NOx Removal: 0.28 #/MBTU / 0.06 #/MBTU 

• 2 ppm NH3 Ammonia Slip 

• ABB Alstom Power Turnkey Contract 

• Cormetech Catalyst (special formulation for oil) 

• First Demonstration of Ammonia on Demand 

(AOD)TM Urea Based Reagent System 

• Commercial Operation - Ozone Season 2000 
Implementation of SCR at Southern Company 

Canal Unit 1 SCR Construction

SCR Modular Construction 

SOUTHERN A 

COMPANY 

Energy to Serve ~ur World" 
Implementation of SCR at Southern Company 

Canal Unit 1 SCR Construction

SOUTHERN A 

COMPANY 

Energy to Serve ~ur World" 
Implementation of SCR at Southern Company

Canal Unit 1 SCR Construction

Ductwork Route In/Out of Building

Lower Catalyst Support Elevation 
Implementation of SCR at Southern Company

Regulated Business 

Commercial

 Plant Size New/Retrofit Fuel SCR System Supplier Catalyst Supplier Operation Date

 Barry 6 500 MW New Natural Gas Vogt / Hitachi Hitachi Jun 2000

 Barry 7 500 MW New Natural Gas Vogt / Hitachi Hitachi May 2001

 Daniel 3 500 MW New Natural Gas Vogt / Hitachi Hitachi May 2001

 Daniel 4 500 MW New Natural Gas Vogt / Hitachi Hitachi May 2001

 Bowen 1 750 MW Retrofit Central App Coal Southern Company Cormetech May 2001

 Bowen 2 750 MW Retrofit Central App Coal Southern Company Cormetech May 2001

 Bowen 3 950 MW Retrofit Central App Coal Southern Company Cormetech May 2003

 Bowen 4 950 MW Retrofit Central App Coal Southern Company Cormetech May 2003

 Hammond 4 530 MW Retrofit Central App Coal Turnkey (TBD) TBD May 2002

 Gorgas 10 780 MW Retrofit Alabama Coal Southern Company Cormetech May 2002

 Wansley 1 935 MW Retrofit Central App Coal Southern Company Siemens May 2003

 Wansley 2 935 MW Retrofit Central App Coal Southern Company Siemens May 2003

 Wansley 6 500 MW New Natural Gas Vogt / Hamon RC Ceram/Frauenthal Jun 2002

 Wansley 7 500 MW New Natural Gas Vogt / Hamon RC Ceram/Frauenthal Jun 2002

 PRB Test Pilot Test PRB Coal Southern Company Cormetech July 2000

Siemens

Haldor Topsoe
Implementation of SCR at Southern Company

Non-Regulated Business

Commercial

 Plant Size New/Retrofit Fuel SCR System Supplier Catalyst Supplier Operation Date

Birchwood 240 MW New Central App Coal ABB/CE Siemens Nov 1996

Canal 1 600 MW Retrofit No. 6 Fuel Oil ABBES Cormetech May 2000

Canal 2 600 MW Retrofit No. 6 Fuel Oil ABBES Cormetech TBD

Contra Costa 6 340 MW Retrofit Natural Gas TBD TBD Spring 2003

Contra Costa 7 340 MW Retrofit Natural Gas B&W TBD Spring 2001

Contra Costa 8 600 MW New Natural Gas TBD TBD Feb 2003

Pittsburgh 5 325 MW Retrofit Natural Gas B&W TBD Spring 2002

Pittsburgh 6 325 MW Retrofit Natural Gas B&W TBD Spring 2002

Pittsburgh 7 720 MW Retrofit Natural Gas TBD TBD Spring 2003

Potrero 3 207 MW Retrofit Natural Gas TBD TBD Spring 2004

Potrero 4 600 MW New Natural Gas TBD TBD Feb 2003

Goat Rock 1 500 MW New Natural Gas Vogt / Hamon RC Ceram/Frauenthal Jun 2002
 

• Approximately 15,000 MW of SCR Projects 

- 26 Active Projects, 15 Regulated, 11 Non-regulated 

- 9600 MW Regulated and 5,400 MW Non-regulated 

- 5000 MW New, 10,000 MW retrofit 

- 6800 MW coal, 1200 MW oil, 7000 MW gas 

 

• Diverse Catalyst Supply 

- 4100 MW Plate, 7400 MW Honeycomb, 3500 MW TBD 

- Honeycomb Suppliers: Cormetech, Ceram/Frauenthal 

- Plate Suppliers: Siemens, Hitachi, Haldor-Topsoe 

Summary

Implementation of SCR at Southern Company
• Multiple Contract Methods for Implementation 

- Turnkey EPC 

- Subcontract to Major Equipment Supplier 

- Self Perform EP 

- Alliance (future) 

 

• No Regrets Strategy 

- Variety of NOx Control Technologies Used 

- SCR Deployed on Large, High Capacity Units 

- Least Cost Compliance Utilizing Averaging Plans 

- Targeted Research to Lower Cost / Increase Performance 

 

Summary 

(continued)

Implementation of SCR at Southern Company
• SCR Implementation Must Consider Regulated 

and Non-Regulated Project Requirements 

 

• Current NOx Research Work 

- PRB Catalyst Testing 

- Advanced Catalyst Formulations 

- Alternate Reagents 

- Balance of Plant Assessment Studies 

- Next Generation Power Generation Technologies 

- Catalyst Regeneration 

- Horizon NOx Control Technologies 

- Combined Pollutant Technologies 

 

Summary 

(continued)

Implementation of SCR at Southern Company