AIR POLLUTION CONTROL

Gas Turbine Uprates (Increased Power)

NOX, SO3, and PM2.5 reduction programs specific to your need

LOW NOx BURNERS (LNB)

Low NOX burners and Low NOX burner Upgrades are available for both industrial and utility boilers burning a wide variety of fuels and have proven to be a cost-effective way to reduce NOX emissions by 40% - 60%. Each system application is specifically designed to maximize NOX reduction without sacrificing combustion performance or unit operation. Computational Fluid Dynamics (CFD) combustion modeling is used to validate the design prior to fabrication of equipment. Lean combustion zones are created for deep staging. These zones inhibit the formation of NOX from fuel bound nitrogen in coal and oil-fired burners. In gas burners the peak flame temperature is reduced to limit thermal NOx formation. NOx reductions can range from 40%-60% depending on the fuel type. Industrial Turbine and Utility Boilers 30-60% NOx Reduction.

Power Plants Fuel Conversion (PPFC)

Fuel Conversion

Crude/HFO/Coal-to-gas conversions are becoming increasingly popular, and they require careful engineering considerations to ensure proper functionality. Natural gas conversion drivers include low natural gas prices, more stringent environmental regulations, and operational flexibility. Typical coal to gas conversion candidates is old sub-critical units with smaller than 500 MW capacity and those with little or no air quality control systems in place. Most of these units are located in the middle eastern and US, burning HFO and coals. Conversion (rather than repowering) allows the option of converting back to solid fuel in the future. TTPS extensive experience in boiler CFD modeling, is now combined with steam-side process simulation to guide Crude/HFO/coal-to-gas conversions.

RESPONSIBILITIES INCLUDE:

• Firing system
  • Burner design and performance
  • Pressure part changes
  • Piping/wind box layout
  • Control systems
• Radiant furnace heat transfer
• Convective pass heat transfer
• Equipment impacts (fans, air heater, APCDs)
  • Performance can be impacted by changed flow distribution, velocity, pressure drop, gas temperature and composition
  • Maintain, mothball, or remove air pollution control devices.

Flue Gas Conditioning

Improve Performance of Electrostatic Precipitators (ESPs) and Capture of Flyash and Particulate Boiler Operations

There are many operational challenges in producing power. TTPS specifically addresses Fuel Flexibility and Slag Control with our In-Furnace Injection Technologies. Our Proven Boiler Performance on a Wide Range of Fuels The ability for a combustion unit to produce economic power may affect the future operation of the unit. Using a variety of fuels can provide flexibility but can also lead to complications operating the boiler.

Technology Provides Fuel Flexibility and Addresses the Following Issues:

• Greater Boiler Efficiency
• Heat Rate Improvement
• Slag/Fouling Reduction
• SOx Plume & Opacity Control

Emissions Control

TTPS takes an integrated approach to pollutant emissions from combustion sources. We and our partners continue to innovate and develop new models and modeling tools in the areas of NOx, SO2, and mercury. We put our modeling tools to work for clients, solving problems in a variety of industrial applications. Our partners have modeled over 80 different utility boilers firing a range of fuels including coal, oil, gas, biomass, syngas, TDF and blends of these fuels. Types of systems modeled include arch-fired, cyclone-fired, roof-fired, tangential-fired, turbo-fired and wall-fired units. TTPS primary expertise is in pollutant formation (e.g., NOx control), but we also have experience with furnace performance and operational impacts. TTPS is also support developers on next-generation models to evaluate the performance of Air Pollution Control Devices (APCD) downstream of boilers. A major focus here is the behavior of mercury, sulfur oxides and particulates as combustion products move from the boiler to the stack. Components studied include SCR, ESP, scrubbers and baghouses. In addition to the utility industry, TTPS provides research and consulting services for industrial furnaces (including applications in the steel, aluminum, and glass industries).

TTPS also has extensive experience with on-site experimental programs in the area of emissions control. From program planning to demonstration management and data analysis, TTPS partners and skilled engineers can help in every stage of a testing campaign. Our partners has investigated emission control from lab-scale up to pilot- and full-scale demonstrations.

Oxides of Nitrogen (NOx)

TTPS advises clients on a wide variety of NOx control technologies. We use our CFD and other modeling tools to predict emissions in utility and industrial boilers for integrated NOx control:

• Low NOx burner
• Staging, Overfire Air (OFA), ROFA
• Burner Optimization and Balancing
• Flue Gas Recirculation (FGR)
• Gas and Coal Reburning
• Fuel Lean Gas Reburning (FLGR)
• Selective non-catalytic reduction (SNCR)
• Rich-Reagent Injection (RRI)
• Fuel Blending and Switching
• Biomass and Syngas Co-firing

When we evaluate NOx control strategies, we do more than prediction NOx emissions. TTPS and partners has the tools and expertise to look at aspects of NOx control that affect operation and performance of combustion systems, including:

• Unburned Carbon-in-ash (LOI)
• Water wall Wastage and Corrosion
• Deactivation of SCR Catalyst
• CO Oxidation
• Fouling and Slagging
• Fuel Efficiency
• Furnace Heat Transfer

Sulfur

In some boilers, corrosion rates can be dominated by the presence of reducing gases (CO and H2S) or by the deposition of ash or char containing partially reacted material (sulfur and carbon). Accordingly, TTPS has modeled the evolution of sulfur species in the combustion zone.

The evolution of SO3 in the backpass of a boiler impacts both operation (air heater fouling, low-temperature corrosion) and emissions (visible plumes). TTPS uses models for SO2 oxidation to predict production of SO3.

The impact of SO3 on mercury control has also been studied using TTPS partners mercury process model, SO3 is known to interfere with mercury capture by activated carbon (or unburned carbon in fly ash). SO3 condenses out of the gas phase as H2SO4 when temperatures drop below the H2SO4 dew point. Most power plants operate at flue gas temperatures above the dew point to avoid corrosion. However, many particle surfaces or equipment surfaces may be below the dew point. H2SO4 condenses on the surfaces and on unburned carbon, removing sites for mercury oxidation and absorption.

Mercury

TTPS and partners has extensive expertise in mercury behavior, from mercury control technology assessments to compliance strategies and prediction of mercury emissions. With in-house mercury measurement equipment, TTPS can provide mercury testing support from lab-scale to pilot- and full-scale demonstrations. TTPS can also provide Computational Fluid Dynamics Modeling to asses mixing and distribution for sorbent injection.

Carbon Dioxide

TTPS has developed expertise in CO2 Control technologies, particularly oxy-combustion. In oxy-combustion, fuel is burned with a combination of pure oxygen and recycled flue gas instead of air. This provides a high quality CO2 stream that would be ready for sequestration or use in enhanced oil recovery activities. TTPS has extensively studied retrofitting a typical boiler for oxy-combustion. The different combustion environment present during oxy-combustion leads to difference in gas volumes, gas heat capacities, flame ignition, radiative heat transfer, particle and acid gas clean up requirements, and potential deposition and fouling issues.

TTPS HAS INVESTIGATED:

• Burner Performance
• Char oxidation
• Aerosol Formation
• Slagging & Fouling
• Corrosion
• Soot Formation
• Radiative Heat Transfer
• Mercury Speciation and Emission