# Reinhold Environmental Ltd.

____________________________

2009 NOx-Combustion Round

Table & Expo Presentation

______________________________________

February 9 & 10, 2009, Cleveland, OHCopyright © 2009 Babcock Power Inc.www.babcockpower.com2009 NOx-Combustion/PCUGConferenceRich AbramsBabcock Power Inc.February 10, 2009www.babcockpower.com© Copyright 2009 Babcock Power Inc.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• Summarywww.babcockpower.com© Copyright 2009 Babcock Power Inc.BPI: Single Supplier Of Boiler AndEmissions Control Systems• Reduces risk of performanceconflicts• Best system for the least cost andgreatest value• Full “chute to stack” guaranteeswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Market Drivers Include StateRPS Programswww.babcockpower.com© Copyright 2009 Babcock Power Inc.www.babcockpower.com© Copyright 2009 Babcock Power Inc.Renewable Energy And Biomass• 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 not– CO2neutral or better– Proven, reliable, economical– Key negative factor isemissionswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass Resources In USwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Common Biomass FuelsWood Chips, Wood Sawdust, Wood Bark,Bagasse, Sunflower Seed Hulls, CoffeeGrounds, C&D, Paper Wastewww.babcockpower.com© Copyright 2009 Babcock Power Inc.Fuel Considerations For Boiler DesignFuel parameterFuel parameterImpacted equipment / designImpacted equipment / designWhat does it affect?What does it affect?•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 – tube spacing• Duct and flue gas equipment sizing• Fan sizing / margins•Flue gas flow area – tube spacing•Duct and flue gas equipment sizing•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 required•Grate sizing•Mill Design•Hot air temperature required•Ash initial deformation temp.•T250temperature•Ash initial deformation temp.•T250temperature• Furnace slagging potential• Furnace efficiency / heat absorption•Furnace slagging potential•Furnace efficiency / heat absorption• Sootblowers• Furnace size / platen surface area•Sootblowers•Furnace size / platen surface area•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 requirements• Sootblower application•Tube clear space requirements•Sootblower application•Sulfur/chlorine content•Sulfur/chlorine content• SO2/ SO3HCl production• Acid dew point temperature•SO2/ SO3HCl production•Acid dew point temperature• Potential for AH / duct corrosion• Acid gas removal equipment sizing•Potential for AH / duct corrosion•Acid gas removal equipment sizing•Ash content•Ash content• Ash production• Erosion potential•Ash production•Erosion potential• Ash removal equipment• Flue gas flow area / velocity limits•Ash removal equipment•Flue gas flow area / velocity limitswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass InExistingBoilersBiomass InExistingBoilerswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass Options1. Co-firing in existing boilers2. Retrofit/conversion of existing units3. New boilersPerformance and Design Considerations• Advanced biomass stoker design• Emissions controlwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass Co-Firing Options1. One approach - biomass fuel mixed withcoal and prepared thru the pulverizer– Limits on amount of biomass fuel– Pulverizer capacity issue2. Fire biomass through burners withdedicated biomass grinder3. Combust on a separate/dedicated grateTypically 10% to 20% by heat input limitwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Issues With Biomass Co-Firing WithPulverized 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 limitwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass Co-Firing WithPulverized CoalEvaluate fouling and slagging of the mixed fuelwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass Retrofit/Conversion OfExisting Units• Establish fuels• Evaluate the boiler capacity firing biomass• 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 phasewww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass ConversionsInitial Feasibility PhasePerform rough analysis of the boiler performance and boilermodifications when converted to biomass fuels• Evaluation of new boiler equipment required for firing biomassfuels• Review of retrofitting the new equipment to the existing boiler• Review ultimate analysis including moisture, high heating valueand size distribution of the fuel• Run combustion calculationsto establish a preliminary boilerefficiency, combustion air, flue gas and fuel flow• Review furnace sizefor combustion heat release rates andfurnace retention time• Estimate the maximum boiler steaming capacityfiring biomassfuels and resultant emissionswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass Conversions (Continued)Initial Engineering Phase• Perform heat transfercalculations• Refine the boiler heat balance analysis• Review superheater (SH), boiler and economizer surfaces• Review SH tube metals and pressure drop calculations• Review flue velocitiesthrough tube bundles and draft losses• Calculate airside pressure drop• Evaluate the auxiliary equipmentcapacity for firing wood, whichincludes:– Air heater– Forced draft fan– Induced draft fan• Evaluate emissionsand options for emissions control• Develop preliminary arrangement drawingswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass Conversions (Continued)Phase 3Detail Engineering Phase• Phase 3 includes site development of accurate arrangementdrawings including site equipment interferences. Update theheat transfer performance programsbased on site information.At the closure of Phase 3 the following can be developed:– “Firm” boiler material cost estimate– Adequate drawings to obtain construction costestimatesPhase 4Boiler Equipment Manufacturingwww.babcockpower.com© Copyright 2009 Babcock Power Inc.www.babcockpower.com© Copyright 2009 Babcock Power Inc.NewBoilersNewBoilerswww.babcockpower.com© Copyright 2009 Babcock Power Inc.PressureTempSteam Flow650-1700psig650-960°F100,000-500,000 Lbs/hrTypical ConditionsNew Boilerswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass Power Boiler - Trends•Stokers– Largest installed base– Fuel flexible– Proven, reliable, improved•Bubbling/fluidized bed– Fuel flexible– In-situ SO2control (not req’d for biomass)– Somewhat lower uncontrolled emissions; not sufficient– High parasitic load•Gasifiers– Relatively small scale– Typically combust “syngas” from gasifierwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Independent Customer Comparison50 MWe Net Plant Output624.68(incl. RSCR)667.96Heat input, MBtu/hr120,528129,500Fuel input, lb/hr1,470 psig/950oF1,470 psig/950oFSteam Press/Temp7.1%Heat rate benefit12,635 Btu/kWh13,605 Btu/kWhPlant heat rate2,324 kW(incl. RSCR)5,430 kWAux power req’s5.9%S.G. size reductionAdvanced StokerBubbling BedBoiler Typewww.babcockpower.com© Copyright 2009 Babcock Power Inc.Goals of Today’s Advanced StokerCombustion Systems1. Efficient combustion– Low unburned carbon– Low carbon monoxide emissions2. Stable combustion– Stable heat input resulting in stable boilersteaming conditions3. Low parasitic losses4. High boiler efficiency– Low stack temperature– Low excess air– High steam temperature– High boiler pressureTo meet current regs, APC systems minimize NOX, CO, PM emissionswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Advanced BiomassStoker Design• Consist of bothcombustion andboiler components• Complete system,not standalonecomponentsBiomass Stoker Technologywww.babcockpower.com© Copyright 2009 Babcock Power Inc.Typical Advanced Biomass StokerBoiler SystemOscillating/vibratingwater cooled stokerUndergrate air zoneFueldistributionRadiant SH for 955°FFurnace height forretention timeOverfire airFurnacearchesEconomizerAirheater for 600°Fcombustion airSand separation forcinder reinjectionCinder reinjectionBoiler pressure 1650 psiEnvironmentalEquipmentwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Typical Applicationswww.babcockpower.com© Copyright 2009 Babcock Power Inc.EmissionsControlEmissionsControlwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass IssuesPollutantTypicalEmissions• PM Low (ESP)• SO2Low• HCl Low• CO Moderate• VOC Low• NOXModerate/HighEmissions - The Primary ConcernNOXand CO are main pollutantswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Uncontrolled Emissions(lb/MBtu)CoalBiomass 

# Uncontrolled UncontrolledNOx 0.32 to >1.5 0.15 to 0.48SO2 0.8 to >6.0 <0.08CO 0.04 to 0.15 0.15 to 0.45PM 3 to 15 0.2 to >1.0www.babcockpower.com© Copyright 2009 Babcock Power Inc.ParticulateMatterParticulateMatterwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Electrostatic Precipitator(ESP)– Device that removes wet or dry suspended matter fromcombustion or process gas streams through anelectrostatic process:• Gas Ionization• Particulate Charging• Influence of Electric Fieldwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Electrostatic Precipitator• High efficiency particulatecontrol device– Controls emissions down to0.01 lbs/MBtu (20-30mg/Nm3)• Applicable to a wide varietyof fuels and boiler types– WTC, urban waste– Stoker, CFB, BFB• Size of ESP is a function ofparticle characteristics &gas conditionsTypical ESPwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Electrostatic Precipitators• Very low pressure drop (< 0.75 inches wc)• High collection efficiency (> 99.5% ispossible)• Applied to a wide variety of power andindustrial applications• Able to tolerate “sparklers” from biomassAdvantagesDisadvantages• Sensitive to operating conditions – volume &flue gas chemistrywww.babcockpower.com© Copyright 2009 Babcock Power Inc.Fabric Filter• Fabric filter systems(“Baghouses”)– A particulate laden gas streampasses through a fabric filter bagwhereby the particulate is collectedon 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 Filterswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Pulse Jet Fabric Filter• 4-Chamber Pulse JetFilterFiltrationCleaningwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Fabric FiltersAdvantages• Constant emission control device– Controls emissions to 0.01lbs/MBtu (20-30 mg/Nm3)• Applicable to a wide variety of fuelsand boiler types• Function of particle characteristics &gas conditionsDisadvantages• High pressure drop (6” wg)• Bags can burn, meltClyde Bergemann EECPulse-Jet Fabric Filterwww.babcockpower.com© Copyright 2009 Babcock Power Inc.NOX/COControlNOX/COControlwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Options to Achieve Low NOXforBiomass Boilers• “Conventional” technologies – limited reduction(OFA/FGR)• SNCR – moderate reduction• Modified SNCR - limited/moderate reduction– Ceramic injection tubes/NH3injection– High pressure rotating OFA/NH3injection• SCR – high reduction efficiencywww.babcockpower.com© Copyright 2009 Babcock Power Inc.Introduction of Specific Nitrogenous Reagents at SpecificTemperature Regimes to Effect a Reducing ReactionPrimary Reaction2NO + NH2CONH2+ 1⁄2O2Ö2N2+ CO2+ 2H2ONITROGEN OXIDE + UREA + OXYGENÖNITROGEN + CARBON DIOXIDE + WATERSelective Non-Catalytic Reduction(SNCR)www.babcockpower.com© Copyright 2009 Babcock Power Inc.Temperature–1600°F to 2200°F (process dependent)Residence Time–0.2 Seconds to 2.0 SecondsBackground Gas Composition– CO, O2, NOXNOXReduction– Baseline and targetReagent Distribution–Access and penetrationCritical SNCR Process Parameterswww.babcockpower.com© Copyright 2009 Babcock Power Inc.AdvantagesIndependent of fuel typeEasily retrofitTunable to specific reduction needsCompatible with other combustion and post-combustion NOXreduction processesRelatively low capital costGood biomass experienceDisadvantagesHigh chemical costLimited removal efficiency (to about 0.09 – 0.15 lb/MBtu)SNCR Processwww.babcockpower.com© Copyright 2009 Babcock Power Inc.LowNOXEmissions Drivers•New England RPS programs require lowNOXemissions– 0.075 lb/MBtu (CT)– 0.065 lb/MBtu (MA, NH)•Applications elsewhere for NOXoffsets•BACT: <0.075 lb/MBtu offered commercially•Avoidance of PSD review (<250 TPY)Typical NOXremoval efficiency required ~ 75%www.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass Options To Achieve LowNOX/CO• “Conventional” technologies can’t get reduction– SNCR– OFA/FGR• “Advanced” technologies can’t get reduction– Ceramic injection tubes/NH3injection– High pressure rotating OFA/NH3injectionConclusion: SCR required to achieve <0.075lb/MBtuwww.babcockpower.com© Copyright 2009 Babcock Power Inc.RSCR 

# System To Reduce NO X 

# Emissions From Biomass Boilerswww.babcockpower.com© Copyright 2009 Babcock Power Inc.Regenerative Selective CatalyticReduction (RSCR)• New technology developed by BPE• Development goal was high thermalefficiency/low total cost for WFB, WTE,and industrial boilers• US Patent # 7,294,321 issued 11/14/07• First SCR system operating on USbiomass boilerwww.babcockpower.com© Copyright 2009 Babcock Power Inc.“Conventional” SCR? 

# Where does it Fit?•Economizer outlet•600° - 800°F•Full flyash loadingwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Biomass and WTE ApplicationsInitial consideration was for“conventional”SCR• Poisons affect all SCR catalysts the same– Potassium, sodium, arsenic are irreversible• High K/Na concentrations in wood ashpreclude use of conventional SCR – veryshort catalyst lifewww.babcockpower.com© Copyright 2009 Babcock Power Inc.Difficult NOXControlApplications• Biomass boilers• WTE furnaces• Boilers with physical constraints (coal,oil)• Process applicationsRequire the use of a “tail-end” SCR systemwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Typical Tail-End SCR Systems• Installed downstream of particulate removal, upstream of stack– Clean gas– Low temperature gas (~ 300°F)• Large physical size, high initial, erection, and operating costs• Typical tail-end unit consists of:– HX– Duct burners– SCR– HX– Fan• NOXreductions 60 - 90%;energy efficiency~ 60 to 75%300FGas- GasHeatExchangerDuct burnerSCRBoosterFanFuel525F300F600F375F50-75F Rise50-75F Risewww.babcockpower.com© Copyright 2009 Babcock Power Inc.Regenerative SCR (RSCR)• Targeted at tail-end applications– Gas relatively free of particulates, poisons (As, Pb,Na/K)– Low SO3content– Low temperature flue gas (approx. 200° to 350°F)• Achieves high heat recovery to minimize energycosts• Modular, standard design to minimize installation cost• Uses proven, guaranteed catalyst• Proven high NOXreductions•Thermal efficiency ~95%(1/10 the fuel of typical tail-endunit)www.babcockpower.com© Copyright 2009 Babcock Power Inc.RSCRFlowSequencewww.babcockpower.com© Copyright 2009 Babcock Power Inc.RSCR Design• Unique ammonia injection mixing• Ceramic media for heat transfer– Provides uniform gas distribution to catalyst• Catalyst bed above heat transfer bed• Multi-chamber design• Beds cycled rapidly to ensure proper gastemperature into catalystwww.babcockpower.com© Copyright 2009 Babcock Power Inc.RSCR Thermal Module• Based on conventional RTO/RCO system• Over 4000 RTO units in operation since early80’s– Many industries; low gas temperature; particulateladen• Issues on media, controls, valving, etc. havebeen solvedKey modification is addition of mixers, reactant,and catalyst dynamicswww.babcockpower.com© Copyright 2009 Babcock Power Inc.RSCR-CO• Ongoing BPEI development program toenhance the technology• Proven precious metal catalyst on metalmonolith• Performance is 50 to >75% reduction of CO• Low (<1” WG) pressure drop across each bed 

# Enables simultaneous NO X 

# & CO reductionwww.babcockpower.com© Copyright 2009 Babcock Power Inc.Modular ConstructionRSCR Features (cont’d)www.babcockpower.com© Copyright 2009 Babcock Power Inc.Installing CatalystModulesHeadspace BurnersRSCR Features (cont’d)www.babcockpower.com© Copyright 2009 Babcock Power Inc.RSCR- Commercial Unitswww.babcockpower.com© Copyright 2009 Babcock Power Inc.50 MW RSCR Systemwww.babcockpower.com© Copyright 2009 Babcock Power Inc.2010N/A0.0752 trains / 4canisters0.25C&DRDF2 X 35MahoneyCounty2010CT / MA0.0654 canisters0.25C&D/WTC38PalmerRenewables2010N/A0.0752 trains / 6canisters0.22Tire derive fuel2 X 50ErieRenewablesOct.2008CT / MA0.0656 canisters0.26Whole tree chipsUrban wood54BurlingtonElectricOct.2007CT Earned RECsevery quarter0.0752 canisters0.28Whole tree chips16BridgewaterPowerDec.2004CT Earned RECsevery quarter0.0752 trains / 5canisters0.25Whole tree chipsWaste woodC&D50BoralexStrattonOct.2004CT Earned RECsevery quarter0.0751 train / 3canisters0.25Whole tree chips15NewHampshireStartDateRenewableEnergyCertificatesGuaranteedNOXOut*lb/MbtuRSCRLayoutNOXInlb/MbtuFuelBoilerSizeMweSiteRegenerative Selective Catalytic Reduction(RSCR) Experience List*RSCRs have demonstrated continuous NOXreduction significantly below the guaranteed levelswww.babcockpower.com© Copyright 2009 Babcock Power Inc.RSCR Guarantees• Emissions guarantee–Outlet NOX–NH3slip• Catalyst life• Project schedulewww.babcockpower.com© Copyright 2009 Babcock Power Inc.Cost InformationPLANT GROSS MW 50GROSS HEAT INPUT, MMBTU/HR 642NOXREMOVED, TONS/YEAR 499AMMONIA COST, $/TON NOX$419NATURAL GAS, $/TON NOX$296POWER COST, $/TON NOX$729CATALYST COST, $/TON $477CAPITAL COST, $/TON $1,978TOTAL COST PER TON NOXREMOVED $ 3,603 ($0.0043/kW)www.babcockpower.com© Copyright 2009 Babcock Power Inc.RSCR - Summary• Patented, proven technology for biomass• High NOXremoval efficiency• Capable of simultaneous CO reduction• Low energy consumption (>95%recovery)• Guaranteed performanceEnables biomass to be cleanrenewable energywww.babcockpower.com© Copyright 2009 Babcock Power Inc.Summary• Biomass is a sustainable renewable resource• Fuel is plentiful in certain parts of the country• Growth rate for new biomass power projectsis high• Trend is to use well proven, efficient, andreliable combustion technologies• Trend is to lower emissions, which can becontrolled to low levelswww.babcockpower.com© Copyright 2009 Babcock Power Inc. 

# Thank You!Questions?Rich Abrams508 854 1140rabrams@babcockpower.com