ETECnology® - ETEC, Entropy Technology & Environmental ...

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Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology Entr Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technol ETECnology ® Innovative Approaches for Achieving Optimal Environmental Energy Synergies • NOx Control Strategies • Optimal Combustion Performance • Plant Energy Utilization Strategies 1 Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology Entr Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technology & Environmental Consultants Entropy Technol

ETECnology ®

Innovative Approaches

for

Achieving Optimal Environmental

Energy Synergies

• NOx Control Strategies

• Optimal Combustion Performance

• Plant Energy Utilization Strategies

1

ETEC BACKGROUND

• ETEC was formed in 1998 with offices in Houston, TX.

• ETEC is a HUB-Vendor ID No. 1760562309300/33538.

• ETEC is TBPE certified to offer and perform engineering services

in Texas (Reg. No. F-7620).

• ETEC pioneered and patented the application of Induced Flue Gas

Recirculation (IFGR) for NOx control.

• ETEC developed combustion optimization procedures for improving boiler

performance and reducing NOx emissions.

• ETEC developed plant/system-wide energy utilization strategies for improving

energy/product ratios, operation, and maintenance.

• The goal of each project has been to achieve optimal synergy between energy

and environmental requirements.

2

NOx Control

Technology

IFGR Systems

Combustion Mods

Slip-Stream IFGR

ETECnology®

ETEC’s line of products and services

Combustion

Technology

Combustion Optimization

Burner System Mods

Operational System Mods

Maintenance

Plant Services

De-bottlenecking

Plant/System-wide

Energy Utilization

Strategies

Boiler/Furnace

Monitoring

3

NOx Control Technology

4

IFGR Systems

• ETEC engineers pioneered IFGR on the first three electric utility boilers at

Entergy and Reliant Energy (via EPRI TC programs), and subsequently on

42 additional units representing a firing capacity of over 123,011 MMBtu/hr!

� ETEC’s Patented IFGR systems have demonstrated NOx reductions as

high as 88% with existing burners, as well as with low NOx burners.

� Our clients now select IFGR as the primary retrofit NOx control technology

for their boilers.

� ETEC is the nation’s leading provider of IFGR technology to the electric

utility industry. ETEC’s IFGR systems comprise > 85% of all operating

IFGR systems on electric utility boilers.

5

ETEC IFGR SYSTEM CLIENTS

Electric Utilities Industry

• Entergy (18) • ExxonMobil (9)

• Reliant Energy (10) • BASF

• TXU (2) • MeadWestvaco

• LCRA (2) • Celanese

• Exelon (2) • Deltec (2)

• Brazos Electric • Georgia Pacific

6

ETEC IFGR Engineering, Design and

Construction Experience

Engineering Design Construction/Installation

7

BOILER/HEATER SIZE, LB/MMBTU

9000

8000

7000

6000

5000

4000

3000

2000

1000

0

GaPacific#6

Deltech 12

Deltech 13

MONROE 10

BASF 20A

EXXON 15

EXXON 16

ETEC IFGR SYSTEMS BOILER-HEATER SIZE RANGE

EXXON 17

EXXON 18

EXXON 19

MONROE 11

PETROCHEM

LASTA 10

LASTA 11

Mead

EXXON 33

EXXON 34

LASTA 1A

LASTA 2A

LASTA 3A

MONROE 12

LASTA 12

EXXON 22

EXXON 32

8

BRAZOS 2

Exelon MC 6

Exelon MC 7

SAB1

SAB2

SRB3

SRB4

THW2

WAP3

LCRA

WEB3

LCRA 2

Graham2

LG2

GBY5

WAP4

PHR1

PHR2

MI3

WG3

SAB 4

PHR3

NM4

NM5

GA1

TH2

NOx EMISSIONS, lb/mmbtu

1.20

1.15

1.10

1.05

1.00

0.95

0.90

0.85

0.80

0.75

0.70

0.65

0.60

0.55

0.50

0.45

0.40

0.35

0.30

0.25

0.20

0.15

0.10

0.05

0.00

GaPacific#6

Deltech 12

Deltech 13

MONROE 10

BASF 20A

EXXON 15

EXXON 16

EXXON 17

EXXON 18

ETEC IFGR SYSTEMS NOx EMISSIONS: BASELINE & IFGR

EXXON 19

MONROE 11

PETROCHEM

LASTA 10

LASTA 11

Mead

EXXON 33

EXXON 34

LASTA 1A

LASTA 2A

LASTA 3A

MONROE 12

Baseline

IFGR

Predicted

LASTA 12

EXXON 22

EXXON 32

9

BRAZOS 2

Exelon MC 6

Exelon MC 7

SAB1

SAB2

SRB3

SRB4

THW2

WAP3

LCRA

WEB3

LCRA 2

Graham2

LG2

GBY5

WAP4

PHR1

PHR2

MI3

WG3

SAB 4

PHR3

NM4

NM5

GA1

TH2

The NOx Control Paradigm Shift

� In the past, primary consideration was given to LNB, OFA, Forced FGR,

etc., all of which are major equipment-intensive technologies and are very

costly ($8-$35 per kW).

� With ETEC’s patented extractor/Inducer IFGR technology

advancements, NOx reductions up to 85% have been achieved with

costs reduced to $1-$3 per kW.

� As a result, IFGR is the 1 st technology considered for gas/light oil

utility boiler NOx control.

� The paradigm shift is widely recognized within the industry as EPRI

(Electric Power Research Institute) has stated “IFGR is by far the

most cost effective NOx control technology for gas/oil fired boilers”.

10

Combustion Modifications

� Modification of existing combustion equipment to achieve NOx

emissions reductions.

• Modify existing burner components

• Modify existing operation

• Implement combustion modification with existing burner equipment

� Modification of existing combustion control system to maintain

minimum NOx emissions and optimum combustion performance.

11

Slip-Stream IFGR

� Modification of existing ductwork upstream of backend NOx control

system, e.g., SCR, to extract a slip-stream routed back into the forced

draft fan for reducing NOx emissions ahead of backend control

system.

� This application of IFGR significantly reduces the operational cost of

the back end control system, e.g., for SCR systems the amount of

ammonia usage is greatly diminished.

12

Combustion Technology

13

Combustion Optimization

• Boiler Efficiency Related Factors

- Combustion Related

- Heat Transfer Related

• Boiler Efficiency Losses

• Efficiency Gains

• Boiler Operational Adjustments

- Instrumentation

- Sampling Techniques

- Efficiency Improvement Procedures

- Maintaining Optimum Efficiency

14

Burner System Modifications

• Inspect and Evaluate Combustion Equipment Condition.

- Burner fuel system

- Burner air register system

- Furnace inspection to evaluate combustion problems

� Document burner system maintenance requirements that need to be

addressed prior to initiating combustion optimization program.

15

Operational System Modifications

• Step-By-Step Operational Improvement Procedure.

- Defining excess oxygen vs carbon monoxide characteristic curves

- Evaluate control system stability and repeatability

- Evaluate if design operation is achievable with existing control system

- Define and modify existing excess oxygen curve over load range

• Specify controls and/or equipment modifications for improving

performance.

- Combustion control system modification or upgrades

- Forced draft fans

- Air heaters

- Economizers

16

Maintenance

• Perform burner/fuel system maintenance requirements prior to conducting

performance optimization.

• Establish and maintain records for historical reference.

• Establish protocol for periodic assessment of combustion equipment.

17

Plant Services

18

De-Bottlenecking

• Conduct Plant Audit to Identify Plant Capacity Bottlenecks.

• Quantify Bottleneck Impacts.

• Define Operational Measures and/or Equipment Modification.

• Document Increased Capacity Cost Benefits.

19

Plant/System-wide Energy

• Conduct Plant Audit

• Define Data Requirements

Utilization Strategies

• Select Target Equipment (based on 80/20 rule)

• Complete Maintenance Items

• Maximize Product/Energy Ratio

- Baseline tests

- Combustion process optimization

- Identify additional maintenance/repair items

• Document cost savings

20

Plant/System-wide Energy

Utilization Strategies, con’t

• Develop Performance Monitoring Procedures

• Develop Operator Training Procedures

• Conduct Operator Training

Energy Management Program Benefits

• Raises Bottom Line Profit

• Extends Runtime, Equipment Life, and Reduces Maintenance

• Improved Instrumentation and Controls

21

Plant/System-wide Energy

Utilization Strategies, con’t

Energy Management Program Benefits, Con’t

• Performance Monitoring

• Better Information Tracking

• Improved Environment

22

Boiler/Furnace Monitoring

Installation of furnace camera for monitoring

furnace flames

23

Attachment 1

ETEC APPROACH

FOR

NOx CONTROL

24

NOx EMISSIONS

COMPLIANCE ASSURANCE

ETEC has combined IFGR+C-Mods Technologies on

majority of Electric Utility Boiler Projects to ensure NOx

emissions compliance. ETEC’s approach is two

phased:

• Install and Optimize IFGR Operation

• If additional NOx emissions are necessary, then

implement C-Mods in combination with IFGR to

achieve guarantee level

25

NOx Emissions Reduction, %

100

Combustion NOx Emissions Reduction

90

80

70

60

50

40

30

20

10

Thermal Based-IFGR Stoichiometry Based-BOOS

ETEC IFGR Systems NOx Emissions Reductions

Theoretical

Natural Gas

Refinery Gas

#2 Fuel Oil

#6 Fuel Oil

Celanese B12

Poly. (Theoretical)

0

0 5 10 15 20 25 30 35 40 45 50 55

%Flue Gas Recirculation

26

Comparison of NOx

Cost (x1,000 $/MMBtu/hr)

10

8

6

4

2

0

LNB

control technology costs

LNB+FGR

40 50 60 70 80 90 100

% NOx Reduction

(Demonstrated)

SCR

IFGR

27

ETEC Offices

11906 Moorcreek

Houston, TX 77070

281-807-7007 Phone

281-807-1414 Fax

Web: www.etecinc.net

28

Attachment 2

ETEC IFGR INSTALLATION

SHOWCASE

29

815mw B&W Opposed Fired Supercritical

30

750mw CE T-Fired Supercritical

31

570mw B&W Opposed Fired Supercritical

32

565mw FW Opposed Fired Supercritical

33

500mw FW Face Fired

34

425mw FW Face Fired

35

350mw CE T-Fired

36

125mw B&W Face Fired

37

600klb/hr CE T-Fired Refinery Boilers

38

450klb/hr B&W Face Fired Paper Mill Plant Boiler

39

350klb/hr B&W Face Fired Petrochem Boiler

40

150klb/hr B&W Face Fired Chemical Plant Boiler

41

IFGR Improves Flame

Characteristics

Baseline Flames IFGR Flames

42

43

44

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