Selective Catalytic Reduction (SCR)

September 19, 2012

.1
 Agenda
Company Overview

Technology Review

Inlet Temperature Management

Ash Management
Catalyst Selection
Ammonia Systems
Flow Modeling

Equipment General Arrangement

Project Execution

Experience List

.2
 B&W is technically, financially
and strategically positioned to support you
through our nations energy transformation

Headquarters: Charlotte, NC
Incorporation: Delaware
Company CEO: E. James (Jim) Ferland
Profile 12,700 plus 10,400
Employees:
joint venture employees
Ticker Symbol: NYSE: BWC

A leader in clean energy technology and services, primarily for the fossil,
nuclear and renewable power markets, as well as premier advance technology
and mission critical defense contractor.
.3
 A Global Business

$2.7B sales. $5.2B backlog. 23,000 employees. 32

countries.
.4
The Babcock & Wilcox Company

Babcock & Wilcox Babcock & Wilcox

Babcock & Wilcox Babcock & Wilcox Babcock & Wilcox
Nuclear Operations
Power Generation Nuclear Energy, Technical Services
Modular Nuclear
Group, Inc. Inc. Group, Inc.
Energy, Inc. Group, Inc.
Coal-fired power Field services Design, Virginia-Class Nuclear material
generation Plant development submarine handling,
Service, and program storage
modifications
deployment of and security
operation Component
Ford-Class
B&W mPowerTM
and maintenance carrier Nuclear
manufacturing small modular
Construction and program laboratories
and reactor
EPC installation technology Refueling Weapons
Environmental Fuel design, Fuel complex
systems (FGD, enrichment processing Decontamination
SCR, Hg, and and and
Particulate, fabrication fabrication decommissionin
Carbon) g
Renewables Strategic
(Biomass, solar, Petroleum
waste-to-energy) Reserve

.5
 B&W Power Generation Group (B&W PGG)
Business Footprint Product Line Portfolio
Utility and industrial boilers
Firing fossil fuels

Environmental products
Control regulated emissions

Boiler cleaning and auxiliaries

$1.7 B Revenue LTM
$2.5 B Backlog
Field services
Headquartered in Barberton, OH
Upgrade, replace equipment
Approximately 8,200 employees
(including JVs)

Construction
Install all B&W supplied scope

O&M services
.6
Environmental Products and Services

One Stop Shop for Utility

Our Vision and Industrial Flue Gas Cleaning
needs (Domestic and International)
Assisting customers to develop
least cost compliance plans
Investigative
studies/consulting/testing
OEM (Utility and Industrial)
Aftermarket
Replacement Parts
Service
International

.7
A Complete Environmental Technology Portfolio

Spray Dry Wet Circulating Industrial Fabric Dry Wet ESP /

Dry Filter SO3 Control Multiclone
FGD FGD ESP
Scrubber and WTE
Scrubbers

Mercury Acid Gas CO2 SCR / Low Emissions Aftermarket Construction Ash
Control Dry Sorbent Control NOX Monitoring Services Management
Injection Burner

Total Solutions Provider

.8
Extensive Environmental Field Service Capabilities
150 Environmental
Field Specialists Support and train / retrain O&M
personnel; Inspections and troubleshooting
Field Service
Organization Equipment Remote Consulting Support for troubleshooting,
O&M, process performance, over the phone

50 Software Service Remote Service Contract,

Dedicated to Regulatory Report Generation, On Site/In House Training
Environmental
Emissions
Monitoring Field Service - Install / Startup / Certification,
Full O&M Service Contracts, T&M Preventive Maintenance

Electrical Service - Inspections, Installations,

Engineering, Testing, Optimization
ESP Electrical
and Mechanical Mechanical Service - Inspections, Rebuilds,
Maintenance, Conversions, Complete Installations,
Engineering studies and Optimization

Environmental Commissioning and Testing Supervise

Commissioning environmental equipment start-up and commissioning
activities
and Testing

.9
 Babcock & Wilcox Research Center
Modern laboratories for
basic research on clean
fuel utilization
Pilot plants for combustion,
oxy-firing, emissions
control, and post-
combustion CO2 capture
Collaborations with
universities, national labs,
and industry
Research focused by
business vision and
technology roadmaps

.10
 Clean Energy Technology

B&W mPowerTM modular nuclear reactor

Carbon capture and storage (CCS)

Biomass and energy-from-waste renewables

Environmental controls for fossil power

Solar thermal power

Building on a legacy of fossil and nuclear energy technology

.11
 B&Ws SCR Qualifications
Oldest domestic SCR technology supplier

SCR project integration expertise

Existing unit operation
Design for constructability begin with the end in mind
Customization of design for maximum performance
Cost minimization

Contracts for 32,000 MW of SCR systems worldwide

Contracts for 44,000 MW SCR construction activity

.12
 Agenda
Company Overview

Technology Review

Inlet Temperature Management

Ash Management
Catalyst Selection
Ammonia Systems
Flow Modeling

Equipment General Arrangement

Project Execution

Experience List

.13
What is Selective Catalytic Reduction (SCR)?
A process for the control of
nitrogen oxide emissions from
stationary sources

Catalyst is defined as a
substance that causes or
accelerates a chemical reaction
without itself being affected

In the process, a catalyst

facilitates a chemical reaction
between NOX and ammonia to
produce nitrogen and water
.14
 Principle of SCR Process

4 NO + 4 NH3 + O2 = 4 N2 + 6 H2O

NO + NO2 + 2 NH3 = 2 N2 + 3 H2O

6 NO2 + 8 NH3 = 7 N2 + 12 H2O

.15
 Typical Coal Fired SCR System

Catalyst
Ammonia injection grid (AIG)
Static mixers
Flow distribution devices
Flow straightener
Catalyst cleaning equipment
Catalyst loading equipment

.16
General System Design Parameters
Operating temperature
Min ~585 F
Max 780 F
Velocity in SCR fluework
50 to 60 ft/sec
Velocity through reactor
< 18 ft/sec
NOX performance (coal)
Up to ~90+% reduction or ~0.05 lbs/MBtu
NOX whichever is first achieved
Ammonia slip (coal)
2 - 5 ppm (dependent on fuel)
SO2 to SO3 Conversion
0.25% to 0.5% per layer
Pressure drop
As necessary for requisite
system equipment

.17
 Agenda
Company Overview

Technology Review

Inlet Temperature Management

Ash Management
Catalyst Selection
Ammonia Systems
Flow Modeling

Equipment General Arrangement

Project Execution

Experience List

.18
 Minimum Ammonia Injection Temperature

Formation of ammonium sulfate compounds in pores of catalyst via

capillary precipitation
Temperature range for formation 550 - 600F
Greatly reduces NOX removal
Condition reverses after short term lower temperature operation
when temperature is raised above 600F and compounds vaporize
SO3 reacts with NH3 to form NH4HSO4 (ammonium bisulfate)
Sticky solid
Forms at 400 - 450F

.19
Options to Raise SCR Inlet Temperature

Wide load operating temperature can

be achieved through:
Economizer flue gas bypass
V-Temp Economizer
Split economizer
Economizer heating surface removal
Feed water/boiler water mix system
Economizer water bypass
Addition of flue burners

.20
Maximum Temperature Control
Upper temperature limit set to avoid impacts to:
Catalyst
Support structure
Other affected materials
Controlling temperature to achieve 780 can be achieved via:
Boiler cleaning equipment modifications / revised protocol
Economizer or other surface (superheater) modifications
Addition of external heat trap

.21
 Agenda
Company Overview

Technology Review

Inlet Temperature Management

Ash Management
Catalyst Selection
Ammonia Systems
Flow Modeling

Equipment General Arrangement

Project Execution

Experience List

.22
Ash Management

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Ash Types
Fly ash
Small, light particles that remain entrained in flue gas
May result in catalyst erosion
May form layer on top of catalyst typically managed with sonic horns,
sootblowers or both

Bottom ash

Large particle ash (LPA)

Light, porous, irregularly shaped
particles that carry over with flue gas
Cannot be cleaned during operation
Plug individual catalyst cells

.24
 Ash Management Design Options
Solution Function Application
Units w/ compatible
LPA baffle Redirect LPA
economize outlet
LPA screen w/ rappers Capture LPA Any unit
Greater than 20% PRB
Eliminate ash build up
Scalloped vane slots and other high ash
on vanes
coals
Greater than 20% PRB
Boxed catalyst support
Prevent ash collection and other high ash
beams
coals
Greater than 20% PRB
Allow ash to flow freely
Large pitch catalyst and other high ash
through bed
coals
Sootblowers/sonic Avoid ash piling; move All coal-fired
horns/air cannons ash through bed applications

.25
Aerodynamic Approach to LPA Management
Install baffle and/or adjust economizer outlet geometry such that
large ash particles are aerodynamically captured in hoppers
Dependent upon accurate measurement of the ash particles
aerodynamic properties
Density
Drag
Restitution
Friction
Designed using CFD modeling

.26
.27
 Physical Barrier for LPA Management

Assured capture of largest particles

Openings smaller than catalyst pitch
May result in plugging and
maintenance issues
Uses a system of rappers or
sootblowers to remove ash buildup
May require modifications to ash
handling system

Installation of a screen across

opening of economizer outlet flue
or elsewhere in fluework

.29
 Large Particle Ash Screens
Considerations:
Pitch
Screen types
Perforated plate
Wedge wire
Screen materials
Carbon steel
Stainless steel
Conforma Clad coating
UTEx TM 1-120LPA
Cleaning methods
Sootblowing
Rapping

.31
Large Particle Ash Screen Cleaning Devices

Sootblowers

Rappers

.32
 Agenda
Company Overview

Technology Review

Inlet Temperature Management

Ash Management
Catalyst Selection
Ammonia Systems
Flow Modeling

Equipment General Arrangement

Project Execution

Experience List

.33
 Universal SCR Reactor
A reactor designed to
accommodate catalysts
from multiple suppliers for
the NOx reduction required.
Outliers may be excluded
from consideration.
Catalyst support system based
on heaviest catalyst module
Reactor height based on tallest
catalyst module
Access and provisions for
catalyst loading based on
largest catalyst volume
Equipment to handle each type
of catalyst

.34
 Catalyst
Corrugated
Active ingredients:
V, Ti, W
Catalyst sizing based on:
Inlet NOx concentration Honeycomb
NOx reduction level
NH3 slip required
Fuel constituents
Gas flow
Plate
Operating temperature
SO2 to SO3 conversion
Required life

.35
 Catalyst Selection
Fuel and ash characteristics
Fuel type
Bituminous
Sub-bituminous
Lignite
Ash type
Flow characteristics
Hygroscopic
Catalyst type and pitch
Corrugated, honeycomb or plate
Pitch

.36
 Major Catalyst Suppliers

Plate Type
Ceram
Hitachi
Johnson Matthey
Corrugated Type
Haldor Topsoe
Honeycomb Type
Ceram
Cormetech
Johnson Matthey

B&W has experience working with all major catalyst suppliers

.37
Catalytic DeNOX Reaction
Active sites constantly being
regenerated in a cycle
Active site available
Adsorb ammonia
Reaction of NOX with NH3
Regenerate site with O2
Sites busy with NOX reduction
(ammonia) not available
for oxidation
Poisons prevent active sites
from being regenerated in
the cycle

.38
 Catalyst Deterioration Issues

Operating temperatures
Sintering unacceptably above design
Sintering > 800 to 850F

Alkaline metals
Masking
Ash

Arsenic
Poisoning Phosphorus
Other ash constituents

.39
 Typical Catalyst Management Plan
1.2

Addition Replacement Replacement Replacement

of Catalyst 1st Layer 2nd Layer 3rd Layer
1.0
Total Catalyst Activity Ratio

0.8

0.6

0.4

0.2

0.0
0 1 2 3 4 5 6 7 8 9 10
Operating Time (Years)

.45
SO2 to SO3 Conversion

N2
NOX H2SO4 Acid Plume
Boiler SCR NH3 Slip
Outlet Catalyst H2O
SO2
SO3

An undesirable side reaction of an SCR catalyst is

the oxidation of SO2 to SO3
More SO to SO oxidation allowed means a more
2 3
Excess NH3 + SO3
active catalyst product can be used (Ammonium Bisulfate)
More active catalyst means less catalyst volume Air Heater Plugging

Less catalyst may mean a smaller reactor and

support structure

.46
 Mercury Oxidation

Mercury oxidation is highly dependent on:

Mercury speciation entering the SCR
Flue gas temperature
Amount of halogens present in the flue gas
For PRB fuels, typical oxidation across
catalyst ranges from 20 to 30% because
Halogen level in flue gas is typically low
Flue gas temperature is often high

.47
 Catalyst Cleaning
Sonic Horns Purpose is to prevent ash from accumulating at all
Uses small amounts of compressed air
Cannot remove deposits that form due to improper operation
Inexpensive system to install, operate, and maintain

Sootblowers Purpose is to remove ash that has accumulated over 1 shift or 1 day
Rake-type (multi-element) used
Air or steam acceptable
Steam must be superheated to prevent condensate
on catalyst
Can possibly remove deposits that form due to improper operation
Expensive system to install, operate, and maintain

Air Cannons Purpose is to remove ash for re-entrainment

Uses compressed air
Can possibly remove deposits that form due to improper operation
Inexpensive system to install, operate, and maintain

.50
 Catalyst Cleaning Equipment - Sonic Horns
Arrangement
Spacing
Single & multiple walls
Flush or inset
Level or sloped
Insulation
Operation (PRB firing)
Begin with 10 sec on / 10 sec off
Pairing (1&2, 3&4)
Sequencing (1&2, 2&3)

.51
 Catalyst Cleaning Equipment - Sootblowers
Media may be either
Air
Clean, dry & oil-free
65-110 ft/sec
ISO 8573-1
Particulate (1 0.1 , 0.1 mg/m3)
Moisture dew point (3 -20C, -4F)
Oil content (2 0.1 mg/m3)
Steam
Superheated (dry)
65-110 ft/sec
Thermal drain

.54
Catalyst Cleaning Equipment Air Cannons

Locate to address specific

problem areas
Relatively new application
of proven technology
Easy to retrofit

.55
 Agenda
Company Overview

Technology Review

Inlet Temperature Management

Ash Management
Catalyst Selection
Ammonia Systems
Flow Modeling

Equipment General Arrangement

Project Execution

Experience List

.56
 Ammonia Systems
System Pros Cons

Purest form of reagent Hazardous material

Anhydrous Ammonia Lowest reagent cost Shipment and storage issues
Lowest equipment and operating cost Permitting issues

Easy to transport
Shipping traffic
Aqueous Ammonia Not classified as hazardous material
Safety issues (19% vs 29%)
(19% or 29%) if less than 20%
Vaporization costs
Safer than anhydrous

Highest equipment and

Safe material (fertilizer) operating cost
Urea Wet or dry forms Formaldehyde issue (?)
Easy to transport Byproduct requires disposal -
classification unclear

.57
Manifold Valve Station

.63
 Ammonia Injection and Mixing
B&W customizes injection zones and hybrid vane
vortex mixers to enable
Zone-by-zone control
Straightforward initial tuning
Infrequent future tuning
Flexibility to accommodate
unit operation changes
Acceptable NH3/NOX and
temperature distributions
without unnecessary
ash collectors

.64
Ammonia Injection and Mixing Equipment
Mixing Devices
Vortex Blending from counter rotating downstream vortices
and general turbulence
Benefits: minimal equipment with low weight
Drawbacks: requires turbulent flow and significant
downstream flue length, P

Vane Blending from translocation, shear and downstream

turbulence
Benefits: control over the process and P/L
efficiency
Drawback: higher weight

B&W Customized for optimum mixing based on:

Distribution of temperature and NOx
Space
AIG
Benefits: enhanced distribution, compatible with
restricted downstream flue length, minimal pressure

.65
 Agenda
Company Overview

Technology Review

Inlet Temperature Management

Ash Management
Catalyst Selection
Ammonia Systems
Flow Modeling

Equipment General Arrangement

Project Execution

Experience List

.66
 Flow Modeling
Use both physical and Computational Fluid Dynamic (CFD) modeling

In addition to temperature, velocity

and NH3:NOX distributions as required by
the catalyst supplier for the NOX reduction
for the project, use modeling to:
Avoid recirculation areas and ash drop out
Avoid horizontal perforated plates
Test ash drop out and re-entrainment
Study ash distribution

.67
CFD Modeling of Flue Gas Velocity

.68
CFD Modeling of NH3 / NOX Ratio

.69
Physical & CFD Modeling of Ash

.70
 Agenda
Company Overview

Technology Review

Inlet Temperature Management

Ash Management
Catalyst Selection
Ammonia Systems
Flow Modeling

Equipment General Arrangement

Project Execution

Experience List

.71
 SCR Reactor Design Options
An array of design options enables selecting an approach
that best fits the plant and its site.
Flat panel delivery for
restricted delivery access,
arrangement and erection
challenges
Truck-shippable modules when
there is adequate space for
laydown and cranes; adequate
access for placement
Barge-shippable modules
when there is water access with
unloading capability; open area
for placement with large cranes

.72
Reactor Modularization

Design goals:
Reduced cost
Enhanced quality
Enhanced safety
Reduced schedule risk
Reduced impact to plant operations
.73
Completed Reactor

.107
Flue Arrangement

.112
 Do's & Don'ts of Flue Arrangements
Flue gas velocity in general Gas Speed Ft/Min)

should be held at a minimum 3800

3000 fpm at full load to minimize 3300

ash build up in 2800

the flues 2300

Flue gas velocity in general 1800

should be held at a maximum of 1300

4000 fpm at full load to minimize 800

ash erosion on flue plate and any

internals. Higher speeds would
increase pressure drop in the
system
Flue transitions should maintain
a constant velocity to minimize
ash build up

.113
 Arrangement Tips

FLOW

ASH BUILD
FLOW
UP AREA

POOR FLUE ARRANGEMENT

FLOW

GOOD FLUE ARRANGEMENT

.114
 Arrangement Tips

FLOW

EQUIPMENT INLET LARGER FLOW AREA AT

OR OUTLET FLUE END OF TRANSITION

FLOW
GOOD FLUE ARRANGEMENT
SAME CROSS SECTIONAL AREA MAINTAINED
ASH BUILD
UP AREA
EQUIPMENT INLET
OR OUTLET FLUE

POOR FLUE ARRANGEMENT

CROSS SECTIONAL SIGNIFICANTLY REDUCED
.115
Catalyst Loading

.118
Catalyst Lifting Rig

Quick Disconnect

.119
Hinged & Bolted Catalyst Loading Door

.121
Catalyst Gas Seals - Ash Shields

.122
Structural Support Steel

.125
Mirant Morgantown SCR Feb. 3, 2005.
 Structural Steel
Structural steel is the backbone of the project
Significant cost, both material and erection labor
Major project schedule impacts
Coupled with the flues and the reactor, defines the
complexity of the project
Independent steel structure generally more cost-effective
Required reinforcement of existing steel less favorable

A successful SCR retrofit

is more than NOX reduction

.126
Mirant Morgantown SCR Feb. 3, 2005.
B&W Structural Steel Experience

.129
 Agenda
Company Overview

Technology Review

Inlet Temperature Management

Ash Management
Catalyst Selection
Ammonia Systems
Flow Modeling

Equipment General Arrangement

Project Execution

Experience List

.130
 Retrofit SCR/Boiler Relationship
The SCR is not simply an add on
The SCR system must be designed to work efficiently
with the boiler, other AQCS equipment and peripherals
Boiler and boiler peripherals modifications may be
necessary as part of SCR installation to achieve the
optimum solution
The SCR system must be integrated with boiler
operation to achieve least-cost NOX compliance

.131
 SCR Design Information
Detailed and accurate information enables realistic project
planning and precludes (or minimizes) false starts
Boiler and peripherals design and performance
data including
Gas flow
Economizer exit gas temperature
NOX in flue gas
Ash carryover information
Drawings site plans, general arrangements, major
equipment drawings
Fuel analyses for fuel(s) that will be fired with SCR in place
Performance goals
Site constraints
Future plans

.132
 Integrated Design Process
The Steps:
1. Define scope explicitly
2. Define arrangement - in concert with existing structures
and equipment
3. Define construction approach early
4. Perform joint project management, engineering and
construction reviews
5. Iterate through 2 - 4 above to advance / evolve the design

A Process, not an Event!

.133
 Agenda
Company Overview

Technology Review

Inlet Temperature Management

Ash Management
Catalyst Selection
Ammonia Systems
Flow Modeling

Equipment General Arrangement

Project Execution

Experience List

.140
B&W SCR System Case Histories

Bruce Mansfield, 1 -3 Sammis 6, 7 Cheswick 1 Karn 1, 2

Campbell 3 Southwest 1 J. T. Deely 2 Sandow 4

.141
 B&W SCR Case History, Bruce Mansfield 1 - 3
Bruce Mansfield 1 - Boiler OEM: Foster Wheeler
3
Boiler MW: 3 x 856
Sammis 6, 7
Boiler Fuel: Bituminous coal / pet coke

Cheswick 1 Inlet NOX: 0.4 lb/106 Btu

NOX Removal: 90%

Karn 1, 2
NH3 System: Aqueous
Campbell 3 Catalyst Type: Hitachi plate@1,054 m3 each; 5.7 & 6.0 mm pitch

Catalyst Life: 19,300 hours

Southwest 1
Popcorn Ash Yes (hopper modifications)
J.T. Deely 2
Outage Length: 12 weeks

Sandow 4 Units 1&2 April 2003

Startup Dates: Unit 3 April 2004
59 month project

.142
 B&W SCR Case History, Sammis 6, 7
Bruce Mansfield 1 - Boiler OEM: B&W
3
Boiler MW: 2 x 680
Sammis 6, 7
Boiler Fuel: Bituminous coal / PRB

Cheswick 1 Inlet NOX: 0.45 lb/106 Btu

NOX Removal: 90%

Karn 1, 2
NH3 System: Aqueous
Campbell 3 Catalyst Type: Cormetech honeycomb

Catalyst Life: 26,000 hours

Southwest 1
Popcorn Ash Yes (screen installed)
J.T. Deely 2
Outage Length: 12 weeks (U6); 8 weeks (U7)
Unit 6 April 2010
Sandow 4 Startup Dates:
Unit 7 May 2010

.143
 B&W SCR Case History, Cheswick 1
Bruce Mansfield 1 - Boiler OEM: CE (Alstom)
3
Boiler MW: 580; corner-fired
Sammis 6, 7
Boiler Fuel: Eastern bituminous

Cheswick 1 Inlet NOX: 0.4 lb/106 Btu

NOX Removal: 80%

Karn 1, 2
NH3 System: Aqueous

Campbell 3 Catalyst Type: Ceram Frauenthal honeycomb@574 m3; 6.7 mm pitch

Catalyst Life: 24,000 hours

Southwest 1
Outage Length: 9 weeks
J.T. Deely 2 Startup Date: May 2003; 23 month project

Sandow 4

.144
 B&W SCR Case History, Karn 1, 2
Bruce Mansfield 1 - Boiler OEM: CE / B&W
3
Boiler MW: 2 x 265
Sammis 6, 7
Boiler Fuel: PRB blend

Cheswick 1 Inlet NOX: 0.45 lb/106 Btu (Unit 1), 0.38 lb/106 Btu (Unit 2)

NOX Removal: 89% (Unit 1); 87% (Unit 2)

Karn 1, 2
NH3 System: Urea
Campbell 3 Catalyst Type: Cormetech honeycomb

Catalyst Life: 16,000 hours

Southwest 1
Popcorn Ash: Yes (screen installed)
J.T. Deely 2
Outage Length: 8 weeks
Unit 1 May, 2004;
Sandow 4 24 month project
Startup Date: Unit 2 May, 2003;
36 month project

.145
 B&W SCR Case History, Campbell 3
Bruce Mansfield 1 - Boiler OEM: Foster Wheeler
3
Boiler MW: 871
Sammis 6, 7
Boiler Fuel: PRB

Cheswick 1 Inlet NOX: 0.27 lb/mmBtu

NOX Removal: 80%

Karn 1, 2
NH3 System: Urea

Campbell 3 Catalyst Type: Cormetech honeycomb

Catalyst Life: 16,000 hours

Southwest 1
Outage Length: 4 weeks
J.T. Deely 2 Startup Date: 2007; 24 month project

Sandow 4

.146
 B&W SCR Case History, Southwest 1
Bruce Mansfield 1 - Boiler OEM: Riley Stoker
3
Boiler MW: 1 x 195
Sammis 6, 7
Boiler Fuel: PRB

Cheswick 1 Inlet NOX: 0.45 lb/106 Btu

NOX Removal: 79%

Karn 1, 2
NH3 System: Urea

Campbell 3 Catalyst Type: CERAM honeycomb

Catalyst Life: 24,000 hours

Southwest 1
Popcorn Ash: Yes (screen installed)
J.T. Deely 2 Outage Length: 6 weeks

Sandow 4 Startup Date: December 2008

.147
 B&W SCR Case History, J.T. Deely 2
Bruce Mansfield 1 - Boiler OEM: CE (Alstom)
3
Boiler MW: 1 x 446
Sammis 6, 7
Boiler Fuel: PRB

Cheswick 1 Inlet NOX: 0.16 lb/106 Btu

NOX Removal: 81%

Karn 1, 2
NH3 System: Aqueous

Campbell 3 Catalyst Type: Johnson Matthey plate

Catalyst Life: 16,000 hours

Southwest 1
Popcorn Ash: Yes (baffle installed)
J.T. Deely 2 Outage Length: 4 weeks

Sandow 4 Startup Date: May 2011

.148
 B&W SCR Case History, Sandow 4
Bruce Mansfield 1 - Boiler OEM: CE (Alstom)
3
Boiler MW: 1 x 591
Sammis 6, 7
Boiler Fuel: Texas Lignite

Cheswick 1 Inlet NOX: 0.20 lb/106 Btu

NOX Removal: 80%

Karn 1, 2
NH3 System: Anhydrous Ammonia

Campbell 3 Catalyst Type: Haldor Topsoe corrugated

Catalyst Life: 24,000 hours

Southwest 1
Popcorn Ash: Yes (screen installed)
J.T. Deely 2 Outage Length: 12 weeks

Sandow 4 Startup Date: April 2010

.149
 Take-Aways
Complete portfolio of air quality control systems to achieve
fully integrated solutions

Decades of experience with SCR system design and in-

depth understanding of PRB challenges

Highly modularized reactor to deliver cost-effectiveness

with quality and safety built in

All company team of designers and erectors to maximize

constructability and assure schedule certainty

Continuous SCR system improvement through research

and development

.150
Thank you.
Questions?

.151