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

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

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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

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SLIDE 1

Initial Operating Results from the First Initial Operating Results from the First B&V Installations of CT B&V Installations of CT-

  • 121

121TM

TM Wet FGD

Wet FGD Technology in North America Technology in North America

Electric Utility Environmental Conference January 30, 2008

Dave Harris

Vice President, AQCS Technology

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01/30/08 EUEC(8) - 2

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

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01/30/08 EUEC(8) - 3

DP&L Killen Station Unit 2 DP&L Killen Station Unit 2

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DP&L Killen Electric Generation Station Unit 2

Manchester, Ohio 635 MW net (2.8 x 106 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

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FGD design parameters

Limestone forced-oxidation FGD producing commercial

gypsum (>95% gypsum, <10% H2O)

Single module of field-wound FRP (87 ft. – 6 in. diameter) 97% SO2 removal Design coals:

Parameter Design high sulfur Typical high sulfur Permit coal HHV, Btu / lb 11,080 11,080 11,649 SO2, lb / MBtu 7.22 6.32 2.82 Cl2, lb / MBtu 0.036 0.036 0.060

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CT-121 Jet Bubbling Reactor (JBR)

Gas Cooler Gas Cooling Pumps Absorber Bleed Pumps Inlet Plenum Outlet Plenum To ME Reaction Tank

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Site arrangement

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Planned versus actual unit load during startup

Planned:

Gradually increasing unit generation to 100%

  • ver 7 days. Unit load as-dispatched thereafter

Compliant coal (400 ppmvd inlet SO2)

Actual Conditions:

Forced outage at Stuart Station (600 MW) Rapid increase to 100% over 36 hours Compliant coal / Nymex coal blend (600 ppm)

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Planned versus actual unit load during startup

100 200 300 400 500 600 700 5/30 6/1 6/3 6/5 6/7

Unit Generation (MW)

Planned Load Actual Load 36 Hr

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Planned versus actual SO2 during startup Planned:

Compliant coal (1.2 lb / MBtu) – startup + 3 days Increasing higher inlet SO2 – 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)

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Planned versus actual SO2 during startup Actual:

Rapidly decreasing blend of

compliant coal and Nymex

100% Nymex within

48 hours (600 ppmvd)

Parametric testing

(400 and 600 ppmvd)

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Planned versus actual inlet SO2 during startup

200 400 600 800 1,000 1,200 1,400 1,600 5/28 6/4 6/11 6/18 6/25 7/2 7/9 7/16 7/23 7/30

SO2 (ppmvd)

Planned Actual

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Initial Performance Results

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Slurry density control

5 10 15 20 25 5/30 6/1 6/3 6/5 6/7 6/9 6/11 Density (wt%)

Suspected density meter calibration error.

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Initial FGD system performance – 1st two weeks

90 91 92 93 94 95 96 97 98 99 100 5/30 6/1 6/3 6/5 6/7 6/9 6/11 6/13 6/15

SO2 Removal Efficiency (%)

Guarantee Reduced efficiency to reduce gypsum production prior to vacuum filter startup

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Initial FGD system performance – parametric testing period June 19 to June 27 Reaction Tank pH Sparger 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

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Initial FGD system performance – parametric testing period

90 91 92 93 94 95 96 97 98 99 100 5/28 6/4 6/11 6/18 6/25 7/2 7/9 7/16 7/23 7/30

SO2 Removal (%)

Parametric testing program (SO2, pH, submergence) Guarantee

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Performance following parametric testing

90 91 92 93 94 95 96 97 98 99 100 7/23 7/30 8/6 8/13 8/20 8/27 9/3 9/10

SO2 Removal (%)

Guarantee End of Parametric Testing

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Continuing CT-121 performance

Inlet SO2 increasing to 1,000 – 1,500 ppmvd range pH held at constant at ±4.0 to maximize reagent

utilization

Sparger submergence held constant SO2 removal efficiency varies with inlet SO2

(ranges 95 to 98%)

SO2 removal efficiency is higher than predicted

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Killen observations CT-121 FGD system has demonstrated:

Stable chemistry under normal load variations >97% SO2 removal efficiency capability Reaction tank slurry density control within ±1 wt% pH control within ±0.2 unit Produces commercial-grade gypsum

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PowerSouth Lowman Units 1 and 2 PowerSouth Lowman Units 1 and 2

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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 NOX removed 14,102 tons SO2 removed

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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% SO2 removal Design coal: 2.5% sulfur bituminous

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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 SO2 removal and scrubber operation support unit operations

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AEP Cardinal Unit 2 AEP Cardinal Unit 2

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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

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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% SO2 removal Design coal: 7.5 lb / MBtu SO2 bituminous

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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

  • ccurred

Unit 1 FGD essentially complete; awaiting tie-in

  • utage opportunity

Unit 3 FGD construction continues

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Discussion Discussion