Reinhold Environmental Ltd.

____________________________

2009 NOx-Combustion Round

Table & Expo Presentation

______________________________________

February 9 & 10, 2009, Cleveland, OH
Copyright © 2009 Babcock Power Inc. www.babcoc

2009 NOx-Combustion

Conference

Rich Abrams 

Babcock Power Inc

February 10, 2009
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Agenda

• Introduction

• Babcock Power Inc. • Biomass Drivers, Fuels, and Issues• Biomass in Existing Boilers

• Co-firing• Retrofit/Conversion of Existing Units

• New Boilers• Emissions Control

• PM• NOx/CO

• Summary
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

BPI: Single Supplier Of Boile

Emissions Control System

• Reduces risk of performance 

conflicts

• Best system for the least cost an

greatest value

• Full “chute to stack” guarantees
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Market Drivers Include Sta

RPS Programs
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© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Renewable Energy And Biom

• Biomass energy:

– Renewable energy– Sustainable fuel supply– Significant power generation (15 to 100+ MW– Base load power– Power is generated day or night; wind or no– CO2 neutral or better– Proven, reliable, economical– Key negative factor is emissions
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Biomass Resources In 
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Common Biomass Fuels

Wood Chips, Wood Sawdust, Wood 

Bagasse, Sunflower Seed Hulls, C

Grounds, C&D, Paper Waste
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Fuel Considerations For Boiler Des

Fuel parameter Fuel parameter What does it affect? What does it affect? Impacted equip

Impacted equip

• Ultimate analysis• Heating value

• Ultimate analysis• Heating value

• Air & flue gas flow rates, draft loss• Boiler efficiency, heat rate

• Air & flue gas flow rates, draft loss• Boiler efficiency, heat rate

• Flue gas flow area – t• Duct and flue gas equ• Fan sizing / margins

• Flue gas flow area – t• Duct and flue gas equ• Fan sizing / margins

•• Moisture content Moisture content

• Air & flue gas flow rates, draft loss• Boiler efficiency, heat rate

• Fuel drying & mill capacity

• Air & flue gas flow rates, draft loss• Boiler efficiency, heat rate• Fuel drying & mill capacity

• Grate sizing• Mill Design• Hot air temperature re

• Grate sizing• Mill Design• Hot air temperature re

• Ash initial deformation temp.

• T250 temperature

• Ash initial deformation temp.• T250 temperature

• Furnace slagging potential• Furnace efficiency / heat absorption

• Furnace slagging potential• Furnace efficiency / heat absorption

• Sootblowers• Furnace size / platen 

• Sootblowers• Furnace size / platen s

• Ash mineral analysis:

Na2O, CaO, KO

• Ash mineral analysis:

Na2O, CaO, KO

• Convection pass fouling potential• SCR

• Convection pass fouling potential• SCR

• Tube clear space requ• Sootblower applicatio

• Tube clear space requ• Sootblower application

•• Sulfur/chlorine content Sulfur/chlorine content • SO2 / SO3 HCl production

• Acid dew point temperature

• SO2 / SO3 HCl production

• Acid dew point temperature

• Potential for AH / duc• Acid gas removal equ

• Potential for AH / duct • Acid gas removal equ

•• Ash content Ash content • Ash production

• Erosion potential

• Ash production• Erosion potential

• Ash removal equipme• Flue gas flow area / v

• Ash removal equipme• Flue gas flow area / ve
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Biomass In 

Existing

Boilers

Biomass In 

Existing

Boilers
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Biomass Options

1. Co-firing in existing boilers2. Retrofit/conversion of existing unit3. New boilersPerformance and Design Considerati• Advanced biomass stoker design• Emissions control
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Biomass Co-Firing Option

1. One approach - biomass fuel mixed w

coal and prepared thru the pulverizer

– Limits on amount of biomass fuel– Pulverizer capacity issue

2. Fire biomass through burners with 

dedicated biomass grinder 

3. Combust on a separate/dedicated gra

Typically 10% to 20% by heat input limi
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Issues With Biomass Co-Firing 

Pulverized Coal

• Areas to carefully evaluate

– Fuel handling and mixing– Burners– Boiler fouling and slagging– Environmental equipment (ESP & 

SCR)

BPI study for 150MW unit concluded 10% 

co-firing limit
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Biomass Co-Firing With 

Pulverized Coal

Evaluate fouling and slagging of the mi
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Biomass Retrofit/Conversion 

Existing Units

• Establish fuels• Evaluate the boiler capacity firing biomas• Review required modifications• Perform a feasibility study

– Phase 1 feasibility study– Phase 2 initial engineering phase– Phase 3 detail– Phase 4 modification and start-up phase
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Biomass Conversions

Initial Feasibility PhasePerform rough analysis of the boiler performance and boile

modifications when converted to biomass fuels

• Evaluation of new boiler equipment required for firing bio

fuels

• Review of retrofitting the new equipment to the existing b• Review ultimate analysis including moisture, high heatin

and size distribution of the fuel

• Run combustion calculations to establish a preliminary b

efficiency, combustion air, flue gas and fuel flow

• Review furnace size for combustion heat release rates a

furnace retention time

• Estimate the maximum boiler steaming capacity firing bi

fuels and resultant emissions
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Biomass Conversions (Contin

Initial Engineering Phase• Perform heat transfer calculations

• Refine the boiler heat balance analysis• Review superheater (SH), boiler and economizer surfac

• Review SH tube metals and pressure drop calculations• Review flue velocities through tube bundles and draft lo

• Calculate airside pressure drop• Evaluate the auxiliary equipment capacity for firing woo

includes:

– Air heater– Forced draft fan– Induced draft fan

• Evaluate emissions and options for emissions control

• Develop preliminary arrangement drawings
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Biomass Conversions (Contin

Phase 3

Detail Engineering Phase

• Phase 3 includes site development of accurate arrange

drawings including site equipment interferences. Update 

heat transfer performance programs based on site inforAt the closure of Phase 3 the following can be develope

– “Firm” boiler material cost estimate– Adequate drawings to obtain construction cost estimates

Phase 4

Boiler Equipment Manufacturing
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© Copyright 2009 Babcock Power Inc. www.babcockpower.com

New 

Boilers

New 

Boilers
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Steam Flow Temp Pressure

650-1700 

psig

100,000- 650-960°F

500,000 Lbs/hr

Typical Conditions

New Boilers
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Biomass Power Boiler - Tre

• Stokers

– Largest installed base– Fuel flexible– Proven, reliable, improved

• Bubbling/fluidized bed

– Fuel flexible– In-situ SO2 control (not req’d for biomass)

– Somewhat lower uncontrolled emissions; not suff– High parasitic load

• Gasifiers

– Relatively small scale– Typically combust “syngas” from gasifier
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Independent Customer Compa

50 MWe Net Plant Output

Heat input, MBtu/hr 667.96 624.68 (incFuel input, lb/hr 129,500 120,528Steam Press/Temp 1,470 psig/950oF 1,470 psigHeat rate benefit 7.1%Plant heat rate 13,605 Btu/kWh 12,635 BtuAux power req’s 5,430 kW 2,324 kW S.G. size reduction 5.9%

Boiler Type Bubbling Bed Advanced 
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Goals of Today’s Advanced Stok

Combustion Systems

1. Efficient combustion

– Low unburned carbon– Low carbon monoxide emissions

2. Stable combustion 

– Stable heat input resulting in stable boiler 

steaming conditions

3. Low parasitic losses4. High boiler efficiency

– Low stack temperature– Low excess air– High steam temperature– High boiler pressure

To meet current regs, APC systems minimize NOX, CO, PM 
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Advanced Biomass 

Stoker Design

• Consist of both 

combustion and boiler components 

• Complete system, 

not standalone components

Biomass Stoker Technolo
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Typical Advanced Biomass Stok

Boiler System

Oscillating/vibrating water cooled stokerUndergrate air zone

Fuel distribution

Radiant SH for 955°F

Furnace height for retention time

Overfire air

Furnace arches

Economizer

Airheater for combustion 

Sancind

Boiler pressure 16

E
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Typical Applications
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Emissions 

Control

Emissions 

Control
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Biomass Issues

Pollutant Typical Emission• PM Low (ESP)• SO2 Low

• HCl Low• CO Moderate• VOC Low• NOX Moderate/High

Emissions - The Primary Concern

NOX and CO are main pollutants
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Uncontrolled Emission

(lb/MBtu) Coal Biomass 

Uncontrolled Uncontrolled 

NOx 0.32 to >1.5 0.15 to 0.4SO2 0.8 to >6.0 <0.08 CO 0.04 to 0.15 0.15 to 0.4PM 3 to 15 0.2 to >1.0 
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Particulate 

Matter

Particulate 

Matter
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Electrostatic Precipitato

(ESP)

– Device that removes wet or dry suspended m

combustion or process gas streams through aelectrostatic process:

• Gas Ionization• Particulate Charging• Influence of Electric Field
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Electrostatic Precipitato

• High efficiency particulate 

control device

– Controls emissions down to 

0.01 lbs/MBtu (20-30 mg/Nm3)

• Applicable to a wide variety 

of fuels and boiler types

– WTC, urban waste– Stoker, CFB, BFB

• Size of ESP is a function of 

particle characteristics & gas conditions Typical ESP
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Electrostatic Precipitato

• Very low pressure drop (< 0.75 inches wc)• High collection efficiency (> 99.5% is 

possible)

• Applied to a wide variety of power and 

industrial applications

• Able to tolerate “sparklers” from biomass

Advantages

Disadvantages

• Sensitive to operating conditions – volume 

flue gas chemistry
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Fabric Filter

• Fabric filter systems 

(“Baghouses”)

– A particulate laden gas stream 

passes through a fabric filter bag whereby the particulate is collected on the surface of the fabric

• Major types:

• Pulse-Jet Filters

– Walk-in Plenum or Top Door– Tall Bag Designs– Low, Med, High Pressure

• Reverse-Air Filters
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Pulse Jet Fabric Filter

• 4-Chamber Pulse Jet 

Filter

Filtration

Cleaning
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Fabric Filters

Advantages• Constant emission control device

– Controls emissions to 0.01 

lbs/MBtu (20-30 mg/Nm3)

• Applicable to a wide variety of fuels 

and boiler types

• Function of particle characteristics & 

gas conditions

Disadvantages• High pressure drop (6” wg)• Bags can burn, melt Clyde Bergem

Pulse-Jet Fa
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NOX/CO 

Control

NOX/CO 

Control
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Options to Achieve Low NOX 

Biomass Boilers

• “Conventional” technologies – limited redu

(OFA/FGR)

• SNCR – moderate reduction • Modified SNCR - limited/moderate reduct

– Ceramic injection tubes/NH3 injection

– High pressure rotating OFA/NH3 injectio

• SCR – high reduction efficiency
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Introduction of Specific Nitrogenous Reagents at S

Temperature Regimes to Effect a Reducing Rea

Primary Reaction

2NO + NH2CONH2 + 1⁄2O2 Ö 2N2 + CO2 + 2

NITROGEN OXIDE + UREA + OXYGEN Ö NITROGEN + CARBON DIOXI

Selective Non-Catalytic Reduc

(SNCR)
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 Temperature – 1600°F to 2200°F (process depende Residence Time – 0.2 Seconds to 2.0 Seconds Background Gas Composition – CO, O2, NOX NOX Reduction – Baseline and target Reagent Distribution – Access and penetration

Critical SNCR Process Parame
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Advantages Independent of fuel type Easily retrofit Tunable to specific reduction needs Compatible with other combustion and post-combustion 

reduction processes

 Relatively low capital cost Good biomass experience 

Disadvantages High chemical cost Limited removal efficiency (to about 0.09 – 0.15 lb/MBtu

SNCR Process
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Low NOX Emissions Drive

• New England RPS programs require 

NOX emissions 

– 0.075 lb/MBtu (CT)– 0.065 lb/MBtu (MA, NH)

• Applications elsewhere for NOX offse

• BACT: <0.075 lb/MBtu offered comme• Avoidance of PSD review (<250 TPY)Typical NOX removal efficiency require
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Biomass Options To Achieve 

NOX/CO

• “Conventional” technologies can’t get redu

– SNCR– OFA/FGR

• “Advanced” technologies can’t get reductio

– Ceramic injection tubes/NH3 injection

– High pressure rotating OFA/NH3 injectio

Conclusion: SCR required to achieve 

lb/MBtu
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RSCR

System To Reduce NOX

Emissions From Biomass Bo
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Regenerative Selective Cata

Reduction (RSCR)

• New technology developed by BPE• Development goal was high therma

efficiency/low total cost for WFB, Wand industrial boilers 

• US Patent # 7,294,321 issued 11/14• First SCR system operating on US 

biomass boiler
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“Conventional” SCR?

Where does it Fit?

• Economizer outlet • 600° - 800°F• Full flyash loading
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Biomass and WTE Applicatio

Initial consideration was for 

“conventional”SCR

• Poisons affect all SCR catalysts the sam

– Potassium, sodium, arsenic are irreve

• High K/Na concentrations in wood ash 

preclude use of conventional SCR – vershort catalyst life
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Difficult NOX Control 

Applications

• Biomass boilers• WTE furnaces• Boilers with physical constraints (coal,o• Process applicationsRequire the use of a “tail-end” SCR sys
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Typical Tail-End SCR System

• Installed downstream of particulate removal, upstream of 

– Clean gas– Low temperature gas (~ 300°F)

• Large physical size, high initial, erection, and operating co• Typical tail-end unit consists of:

– HX– Duct burners– SCR– HX– Fan

• NOX reductions 60 - 90%; energy efficiency ~ 60 to 75%

300F

Gas- Gas

Heat 

Exchanger

Duct burner

SCR

BoosterFan

Fuel

525F

300F

375F

50-

50
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Regenerative SCR (RSCR

• Targeted at tail-end applications

– Gas relatively free of particulates, poisons (

Na/K)

– Low SO3 content– Low temperature flue gas (approx. 200° to 3

• Achieves high heat recovery to minimize energ

costs

• Modular, standard design to minimize installat• Uses proven, guaranteed catalyst• Proven high NOX reductions

• Thermal efficiency ~95% (1/10 the fuel of typical t

unit)
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RSCR 

Flow 

Sequence
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RSCR Design

• Unique ammonia injection mixing • Ceramic media for heat transfer

– Provides uniform gas distribution to catalys

• Catalyst bed above heat transfer bed• Multi-chamber design• Beds cycled rapidly to ensure proper ga

temperature into catalyst
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RSCR Thermal Module

• Based on conventional RTO/RCO system• Over 4000 RTO units in operation since e

80’s

– Many industries; low gas temperature; particu

laden

• Issues on media, controls, valving, etc. h

been solved

Key modification is addition of mixers, r

and catalyst dynamics
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RSCR-CO

• Ongoing BPEI development program to 

enhance the technology

• Proven precious metal catalyst on meta

monolith

• Performance is 50 to >75% reduction o• Low (<1” WG) pressure drop across eac

Enables simultaneous NOX & CO redu
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Modular Construction

RSCR Features (cont’d)
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Installing Catalyst 

Modules Headspace 

RSCR Features (cont’d)
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RSCR- Commercial Units
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50 MW RSCR System
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

2 trains / 4 0.075 canisters

Mahoney 2 X 35 C&DRDF 0.25County

Palmer 38 C&D/WTC 0.25 4 canisters 0.065 CT Renewables

2 trains / 6 0.075 canisters

Erie 2 X 50 Tire derive fuel 0.22Renewables

Whole tree chips 0.26 6 canisters 0.065 CT Urban wood

Burlington 54Electric

CT Earevery q

Bridgewater 16 Whole tree chips 0.28 2 canisters 0.075Power

CT Earevery q

2 trains / 5 0.075canisters

Whole tree chips 0.25Waste woodC&D

Boralex 50Stratton

CT Earevery q

1 train / 3 0.075canisters

New 15 Whole tree chips 0.25Hampshire

Rene

En

Certi

Guaranteed 

NOX Out* 

lb/Mbtu

RSCR 

Layout

NOX In 

lb/Mbtu

Boiler Fuel

Size 

Mwe

Site

Regenerative Selective Catalytic Reduct

(RSCR) Experience List

*RSCRs have demonstrated continuous NOX reduction significantly below the guaranteed le
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

RSCR Guarantees

• Emissions guarantee

– Outlet NOX

– NH3 slip

• Catalyst life• Project schedule
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Cost Information

PLANT GROSS MW 50GROSS HEAT INPUT, MMBTU/HR 642NOX REMOVED, TONS/YEAR 499

AMMONIA COST, $/TON NOX $419

NATURAL GAS, $/TON NOX $296POWER COST, $/TON NOX $729CATALYST COST, $/TON $477CAPITAL COST, $/TON $1,978TOTAL COST PER TON NOX REMOVED $ 3,603 ($0.0043/k
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

RSCR - Summary

• Patented, proven technology for bio• High NOX removal efficiency 

• Capable of simultaneous CO reduct• Low energy consumption (>95% 

recovery)

• Guaranteed performance

Enables biomass to be clean renewable 
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Summary

• Biomass is a sustainable renewable res• Fuel is plentiful in certain parts of the co• Growth rate for new biomass power pro

is high 

• Trend is to use well proven, efficient, an

reliable combustion technologies

• Trend is to lower emissions, which can 

controlled to low levels
© Copyright 2009 Babcock Power Inc. www.babcockpower.com

Thank You!

Questions?

Rich Abrams

508 854 1140

rabrams@babcockpower.com