“Enhanced Plant Performance via

Effective SO3 Control”

Sterling Gray, URS CorporationMick Harpenau, Duke Energy

EUEC ConferencePhoenix, AZ

February 3, 2010

2

SO3 Adversely Impacts …

Heat Rate

Air Heater

Reliability

NOx Removal

Mercury Capture

CO2 Emissions

Equipment

Corrosion

3

Impact on Corrosion Potential

220

230

240

250

260

270

280

290

300

310

320

0 10 20 30 40 50 60

SO3 Concentration (ppmv)

Su

lfu

ric

Aci

d D

ewp

oin

t (D

eg F

)

14% H20

12% H20

10% H20

8% H20

6% H20

4

Air Heater Fouling

Ash

Sulfuric Acid

Ammonium Bisulfate

Source: Alstom Airpreheater Company

5

Impact on Heat Rate

$0.7

$1.4

$0.0

$0.2

$0.4

$0.6

$0.8

$1.0

$1.2

$1.4

$1.6

An

nu

al F

uel

Sav

ing

s (

$M/Y

r)

340 305 270

APH Exit Temperature (F)

500 MW Gross9500 Btu/kW-hr85% Cap Factor$2.00/MMBtu

6

Impact on CO2 Emissions

$0.2

$0.8

$0.4

$1.6

$0.0

$0.2

$0.4

$0.6

$0.8

$1.0

$1.2

$1.4

$1.6

$1.8

An

nu

al C

O2 C

red

it V

alu

e ($

M/Y

r)

340 305 270

APH Exit Temperature (F)

$5/ton CO2$20/ton CO2

500 MW Gross9500 Btu/kW-hr85% Cap Factor

7

Impact on NOx Control

• Increase SCR NOx Removal– limit ABS formation via SO3 reduction

– permit operation at elevated NH3 slip

• Extend Useful Life of Catalyst– elevated slip permits lower reactor potential

• Extend Low-Load Operation of SCR– reduce SO3 level at SCR inlet

– lower Min Op Temp (min load)

• Strategy can be Applied to SNCR

8

Impact on NOx Removal

$0.9

$1.8

$2.7

$0.0

$0.5

$1.0

$1.5

$2.0

$2.5

$3.0

An

nu

al N

Ox

Cre

dit

Val

ue

($M

/Yr)

84 88 92 96

SCR NOx Removal (%)

500 MW Gross9500 Btu/kW-hr85% Cap Factor0.5 lb/MMBtu NOx$2500/ton Nox Credit

9

Impact of SO3 on ACI Performance

Injection Concentration (lb/MMacf)0

100

90

80

70

60

50

40

30

20

10

02 4 6 8 10 12 14 16 18 20

Vap

or

Hg

Re

mo

val

Acr

oss

PM

Co

ntr

ol (

%)

WC, FF or TOXECONWC, ESP, brominated carbon

LSEB, ESP

HSEB, ESP

WC = Western Coal

LS = Low Sulfur

HS = High Sulfur

EB = Eastern BituminousSource: EPRI

10

Impact on Hg Capture in Ash

0

2

4

6

8

10

12

14

0 5 10 15 20 25 30 35 40 45

Measured or Estimated SO3 Conc at ESP Outlet (ppm)

Mer

cury

Fra

ctio

n in

Ash

LO

I (u

g/g

)

Plant A

Plant B

Plant C

Plant D

Plant E

Plant D (Downstream) 2009

Plant D (Pre-SCR) 2009

Power (Plant B)

Power (Plant C)

Power (Plant A)

Power (Plant D)

Power (Plant E)

Power (Plant D (Pre-SCR)2009)Power (Plant D (Downstream)2009)

11

Impact on Hg Removal with ACI

0

10

20

30

40

50

60

70

80

90

100

0 lb/Macf 2 lb/Macf 5 lb/Macf 10 lb/Macf

Activated Carbon Injection Rate

To

tal H

g R

emo

val (

%)

No SO3 Removal

With SO3 Removal

Source: EPRI, Mercury Research Center, March 2007

12

Comparison of SO3 Controls

SBS Injection

Mag Hydroxide

Hydrated Lime

Trona Ammonia

Typical Injection Location

Boiler √Before SCR √Before AH √Before ESP √ √ √Before FGD √

Typical SO3 Removal 90 - 98% 80 - 90% 50 - 80% 70 - 90% 80 - 95%

Typical Injection NSR 1 - 1.5 3 - 4 3 - 5 2 - 3 1 - 2

13

SBS Injection™ Technology

Features• Patented Technology• Simple Solution Injection• Sodium-Based Reagent• Dual-Fluid Atomization• Selective Reactions

• High SO3 Removal

• Low Injection Rate• Product Collected with Ash

Benefits• Opacity Elimination• Corrosion Reduction• ESP Enhancement• HCl and Se Removal • Potential Heat Recovery• SCR/SNCR Flexibility• Hg Capture Enhancement

• CO2 Reduction

Maximum Benefits with “Upstream” InjectionMaximum Benefits with “Upstream” InjectionMaximum Benefits with “Upstream” InjectionMaximum Benefits with “Upstream” Injection

14

Simplified SBS Flow Diagram

FE FE

REAGENTSOLUTION STORAGE

TANK

INJECTION FEED PUMP

HOPPER TRUCK

INJECTION AIR:PLANT AIR OR COMPRESSOR

INJECTION LANCES

FLUE GAS

FILTER

DILUTION WATER PUMP

SBS DILUTION WATER

DUPLEXSTRAINER

(SOFTENED)

DILUTION WATERTANK

DE

SOLIDSWETTING

PUMP

15

SBS Injection Locations

SCR Outlet

Air Heater Outlet

SCR Inlet

16

SBS Injection Installations

12,500 MW Installed on 20 Boilers12,500 MW Installed on 20 Boilers12,500 MW Installed on 20 Boilers12,500 MW Installed on 20 Boilers

Utility Plant Location MWDesign

SO3Injection Location

ReagentStartup

Date

FirstEnergy Mansfield 1-3 Shippingport, PA 3 x 860 80 Air Heater Inlet Sodium Sulfite March 2003

TVA Widows Creek 7 Stevenson, AL 550 54 Air Heater Inlet Sodium Sulfite April 2003

NIPSCO Bailly 8 Porter, IN 365 59 Air Heater Outlet Sodium Carbonate April 2004

Vectren Culley 3 Newburgh, IN 287 48 SCR Outlet Byproduct SBS July 2004

PPL Montour 1-2 Washingtonville, PA 2 x 765 42 Air Heater Outlet Sodium Carbonate Aug 2004

Duke Energy Gibson 1-5 E. Mt. Carmel, IN 5 x 650 110SCR Inlet /

Air Heater OutletSodium Carbonate May 2005

DP&L Killen 2 Manchester, OH 635 34 / 36Econ Outlet /

SCR OutletSodium Carbonate Oct 2007

IP&L Harding St 7 Indianapolis, IN 465 58 SCR Outlet Sodium Carbonate Nov 2007

NIPSCO Bailly 7 Porter, IN 180 59 SCR Outlet Sodium Carbonate April 2008

DP&L Stuart 1-4 Aberdeen, OH 4 x 620 90 Econ Outlet Sodium Carbonate Sept 2008

17

SCR First Catalyst Layer

SBS Injection Lances (Par Mixers removed)

Ammonia Injection Grid

Economizer Outlet

TurboMixers

Gibson “Pre-SCR” Injection

18

19

Gibson SO3 Test Results

0

5

10

15

20

25

30

35

40

45

50

Econ Out SCR In AH In ESP Out

Mea

sure

d S

O3, p

pmvd

@ 3

% O

xyge

n

1717 17

< 0.5Avg 0.3

46

38

1.0

< 5.0Avg 2.3

Baseline

SBS Injection

20

520

540

560

580

600

620

640

0 5 10 15 20 25 30 35

SO3 Concentration, ppm

Min

imu

m O

per

atin

g T

emp

erat

ure

, °F

SCR Min Op Temp vs SO3

Δ MOT ~ 80°FΔ MOT ~ 80°F

Baseline – 615°F

With SBS – 635°F

Composite Range of MOT Information Provided by

Catalyst Suppliers

21

Summary

• SO3 Adversely Impacts Plant Performance– Corrosion– AH Fouling– Heat Rate– CO2 Emissions– NOx Removal – Mercury Capture

• SO3 Removal can Generate Millions $ in Benefits– Avoided Forced Outages– Fuel Savings– Lower Environmental Compliance Costs

• SBS Injection Offers Cost-Effective SO3 Control– Treats upstream of SCR / AH– Very high SO3 removal (~98%)– Proven - 20 units - 12,500 MW – 7 yrs

SOSO33 Removal: Removal: It’s not just for It’s not just for

““Blue Plume” anymoreBlue Plume” anymore

SOSO33 Removal: Removal: It’s not just for It’s not just for

““Blue Plume” anymoreBlue Plume” anymore

22

Questions?