Initial Operating Results from the First Initial Operating Results - PowerPoint PPT Presentation

Electric Utility Environmental Conference Initial Operating Results from the First Initial Operating Results from the First TM Wet FGD 121 TM B&V Installations of CT- -121 Wet FGD B&V Installations of CT Technology in North America Technology in North America Dave Harris Vice President, AQCS Technology January 30, 2008

Presentation objectives � Provide description of initial performance of the Killen Unit 2 CT-121 FGD system � Provide updates on recently started CT-121 FGD installations � PowerSouth (formerly Alabama Electric Cooperative) plant Lowman Units 1 and 2 � AEP Cardinal Unit 2 EUEC(8) - 2 01/30/08

01/30/08 DP&L Killen Station Unit 2 DP&L Killen Station Unit 2 EUEC(8) - 3

DP&L Killen Electric Generation Station Unit 2 � Manchester, Ohio � 635 MW net (2.8 x 10 6 acfm) � Balanced draft � Hot-side ESP / SCR � Existing brick chimney flue (designed for 2 units) � Coal delivered by barge � Bottom ash and fly ash sluiced to ponds EUEC(8) - 4 01/30/08

FGD design parameters � Limestone forced-oxidation FGD producing commercial gypsum (>95% gypsum, <10% H 2 O) � Single module of field-wound FRP (87 ft. – 6 in. diameter) � 97% SO 2 removal � Design coals: Design Typical high Parameter Permit coal high sulfur sulfur HHV, Btu / lb 11,080 11,080 11,649 SO 2 , lb / MBtu 7.22 6.32 2.82 Cl 2 , lb / MBtu 0.036 0.036 0.060 EUEC(8) - 5 01/30/08

CT-121 Jet Bubbling Reactor (JBR) Outlet Plenum Gas Cooler To ME Inlet Plenum Absorber Gas Cooling Bleed Pumps Reaction Tank Pumps EUEC(8) - 6 01/30/08

01/30/08 Site arrangement EUEC(8) - 7

Planned versus actual unit load during startup � Planned: � Gradually increasing unit generation to 100% over 7 days. Unit load as-dispatched thereafter � Compliant coal (400 ppmvd inlet SO 2 ) � Actual Conditions: � Forced outage at Stuart Station (600 MW) � Rapid increase to 100% over 36 hours � Compliant coal / Nymex coal blend (600 ppm) EUEC(8) - 8 01/30/08

Planned versus actual unit load during startup 700 Actual 600 Load Unit Generation (MW) 500 400 300 200 Planned Load 100 36 Hr 0 5/30 6/1 6/3 6/5 6/7 EUEC(8) - 9 01/30/08

Planned versus actual SO 2 during startup Planned: � Compliant coal ( 1.2 lb / MBtu) – startup + 3 days � Increasing higher inlet SO 2 – 7 days per step: � 100% Nymex coal ( 1.6 lb / MBtu) � 75% Nymex / 25% medium S ( 2.15 lb / MBtu) � 50% Nymex / 50% medium S ( 2.7 lb / MBtu) � 25% Nymex / 75% ,medium s ( 3.25 lb / MBtu) � 100% medium S ( 3.8 lb / MBtu) EUEC(8) - 10 01/30/08

Planned versus actual SO 2 during startup Actual: � Rapidly decreasing blend of compliant coal and Nymex � 100% Nymex within 48 hours (600 ppmvd) � Parametric testing (400 and 600 ppmvd) EUEC(8) - 11 01/30/08

Planned versus actual inlet SO 2 during startup 1,600 1,400 Planned 1,200 SO 2 (ppmvd) 1,000 800 Actual 600 400 200 0 5/28 6/4 6/11 6/18 6/25 7/2 7/9 7/16 7/23 7/30 EUEC(8) - 12 01/30/08

01/30/08 Performance Results Initial EUEC(8) - 13

Slurry density control 25 Suspected density 20 meter calibration error. Density (wt%) 15 10 5 0 5/30 6/1 6/3 6/5 6/7 6/9 6/11 EUEC(8) - 14 01/30/08

Initial FGD system performance – 1 st two weeks 100 99 SO 2 Removal Efficiency (%) 98 97 96 Guarantee 95 94 Reduced efficiency to 93 reduce gypsum production prior to 92 vacuum filter startup 91 90 5/30 6/1 6/3 6/5 6/7 6/9 6/11 6/13 6/15 EUEC(8) - 15 01/30/08

Initial FGD system performance – parametric testing period June 19 to June 27 Reaction Tank Sparger pH Submergence, in. 5.0 base, ± 4 4.5 base, ± 2.5 4.0 base, ± 2.5, + 4 4.5 base, + 2.5 5.0 base + 2.5 5.0 → 3.8 base 4.3 base EUEC(8) - 16 01/30/08

Initial FGD system performance – parametric testing period 100 99 98 97 SO 2 Removal (%) 96 Guarantee 95 94 93 92 Parametric testing program (SO 2 , pH, submergence) 91 90 5/28 6/4 6/11 6/18 6/25 7/2 7/9 7/16 7/23 7/30 EUEC(8) - 17 01/30/08

Performance following parametric testing 100 99 98 Guarantee SO 2 Removal (%) 97 96 95 94 End of 93 Parametric Testing 92 91 90 7/23 7/30 8/6 8/13 8/20 8/27 9/3 9/10 EUEC(8) - 18 01/30/08

Continuing CT-121 performance � Inlet SO 2 increasing to 1,000 – 1,500 ppmvd range � pH held at constant at ±4.0 to maximize reagent utilization � Sparger submergence held constant � SO 2 removal efficiency varies with inlet SO 2 (ranges 95 to 98%) � SO 2 removal efficiency is higher than predicted EUEC(8) - 19 01/30/08

Killen observations CT-121 FGD system has demonstrated: � Stable chemistry under normal load variations � >97% SO 2 removal efficiency capability � Reaction tank slurry density control within ±1 wt% � pH control within ±0.2 unit � Produces commercial-grade gypsum EUEC(8) - 20 01/30/08

01/30/08 PowerSouth Lowman Units 1 and 2 PowerSouth Lowman Units 1 and 2 EUEC(8) - 21

PowerSouth Lowman Units 1 and 2 � New FGD (CT-121) on Units 1 and 2 � Combined flow � New chimney � FGD Upgrade on Unit 3 � Utilizing existing Units 2 and 3 FGD � Limestone conversion � DCS controls conversion � SCR on Units 2 and 3 � No bypass � Doubled gypsum production � Environmental bottom line � 6,963 tons NO X removed � 14,102 tons SO 2 removed EUEC(8) - 22 01/30/08

FGD design parameters � Limestone forced-oxidation FGD � Single FGD module serving Units 1 and 2 � Alloy 2205 tank with alloy 255 at the bubbling zone � 68’- 0” diameter � 98% SO 2 removal � Design coal: 2.5% sulfur bituminous EUEC(8) - 23 01/30/08

FGD operation � Initial startup on November 27, 2007 with Unit 2 returning from outage � Full load operation of Unit 2 achieved before a scheduled turbine inspection � System tuning to be completed in late January; meanwhile SO 2 removal and scrubber operation support unit operations EUEC(8) - 24 01/30/08

01/30/08 AEP Cardinal Unit 2 AEP Cardinal Unit 2 EUEC(8) - 25

AEP Cardinal Units 1, 2, and 3 � New FGD (CT-121) on Units 1, 2, and 3 � Nominal 600 MW units (each) � Common BOP facilities � Limestone / gypsum systems located near JBRs for Units 1 and 2 � Wastewater treatment � AEP performing balance draft conversion and DCS retrofits on Units 1 and 2 EUEC(8) - 26 01/30/08

FGD design parameters � Limestone forced-oxidation FGD � Single FGD module per unit � Alloy 2205 tank with alloy 255 at the bubbling zone � 89’- 0” diameter (Unit 1 or Unit 2) � 95’-0” diameter (Unit 3) � 98% SO 2 removal � Design coal: 7.5 lb / MBtu SO 2 bituminous EUEC(8) - 27 01/30/08

FGD status � Initial Unit 2 startup on December 15, 2007 with unit returning from outage � Tuning and testing of the Unit 2 FGD has not yet occurred � Unit 1 FGD essentially complete; awaiting tie-in outage opportunity � Unit 3 FGD construction continues EUEC(8) - 28 01/30/08

01/30/08 Discussion Discussion EUEC(8) - 29