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ES StationaryDe-Nox TECHNOLOGY
NOx REDUCTION IN UTILITY & NOx REDUCTION IN UTILITY &
INDUSTRIAL BOILERS
By Mr. Prem Talreja(Head - Stationary India &Managing Director)
Content
S. No
DescriptionS
No.Description
1 Yara at a Glance 8 SNCR Technology
2 Our Portfolio / Offering 9 Proven Technology
3 NOx, its implications 10 Challenges in Power Plant
4 De-NOx technologies 11 Challenges in Monitoring
2
5 Notification of India &
Implementation status
12 Avoid dilution
6 Global Norms of NOx control 13 Conclusion
7 SCR technology 14 Our Future…
Revenues and other income (2017)
US $ 11
Number of employees
15.527
Located in more than
50 countries
27,2 million tons Fertilizers
7,12 million tons
Key numbers
(Appx.)billion
50 countries
Sales to more than
150 countries
Industrial products
2,03 million tons Ammonia trade
3
Yara delivers sustainable solutions for agriculture and the environment
Agricultural Industrial Environmental products products solutions
4
3
We serve a wide range of customers through an extensive offering
Services
• Dispensing bulk
equipment
• Telemetry
• Training
• SCR
Technology
• SNCR
Automotive
• Optimization of
operations,
emissions
Off-road vehicles
Cars
Trucks
• NOxCare:
high-quality
urea solution
End users Yara value proposition Yara competitive edge
Reagent Technology
• AdBlue:
High-quality
urea
solution
Power plants
• Global reach
• Strong market
infrastructure
• Reliable supply
Stationary
Marine
• SCR
Technology
• SOx
scrubbers
• Design and
engineering
• SNCR
Technology
• Hybrid-
systems
• NOxCare40:
High purity
urea solution
emissions
reduction, safety
and performance
improvement
• Commissioning
• Operational
training
• Safety training
• Maintenance
• Spare-parts
Cruise and ferries
Coast-nearvessels
Deep sea vessels
urea solution
and
ammonia
solution
Cement factories
Waste Incinerators
• Proximity to customers
• High-quality products
• Proven technology
• Strong Yara brand
5
Nox reacts with hemoglobin affecting body tissues causing tachycardia, high blood pressure, and arrhythmia
> 15 µg/m3, irritation of the eyes
Nox and its impacts of environment & health
NOx is a generic term for mono-nitrogen oxides, namely NO and NO2. NOx is formed during combustion at high temperatures (above 1350 deg. C).
> 25 µg/m3 dyspnea, asthma crisis
> 150 – 200 µg/m3 pulmonary edema
6
One Study indicates that every coal-based power plant in India is
responsible for around 650 deaths every year: approximately 500 deaths are associated with SO2, 120 with NOx and 30 with PM 2.5.
Emission Standards Notified in India in 2015
7
Implementation-??
Implementation Norms – Current Status
� Environment ministry notifies standards for oxides of nitrogen emissions (NOx)
in 2015. Deadline for implementation: 2017.
� In 2017 further extended to 2022 for Power
� 80% cement sector already implemented the technologies to reduce the NOx
� In 2019, MoP and Power Industry still deliberating norms, limits, technology etc
after 4 years
� Above time scale indicates communication gap between regulator and industry.
� Proactive approach from the industry needs to be exhibited since it involves
health and sustainability of development for future generations.
8
GLOBAL SCENARIO OF EMISSION STANDARDS
Country Time
Period
NOx ,mg/Nm3
existing new
China hourly 100 50
Indonesia (*) 850 200-300
Japan 410 200
USA daily 135 95.3
EU Cont. 200 150
(*) Proposed, implemented from 2020
Eye Opener : Even Spain having type of Coal which is close to the Indian Coal is
Implementing the EU emission Norms
9
DeNOx Technologies
� SNCR
– Boilers / Cogeneration
– Industrial applications
� SCR
– Boilers / Cogeneration
– Industrial applications
� HYBRID
– Boilers / Cogeneration
– Industrial applications
Marin
De-NOx Technology available as secondary measures:
DeNOx Reducing Agents
� Available Reagents:
– Anhydrous ammonia
– Aqueous ammonia
– Solid urea
– Urea solution
NH3 + NOx N2 + H2O
NH3 slip
– Marine
Reasons to Opt for Secondary Measures with Primary measures :
1) In combination of Primary Measure with Secondary Measures , we can go less than100 mg/Nm3.
2) SNCR is a low cost solution with which we can achieve 300 mg/Nm3 as per MoEF notification.
3) Short time of installation with min time of Boiler shut down
10
SCR technology
• New block with SCR system
• RETROFIT - high dust DeNOx
The SCR is the best developed and most widely used method for removing NOx from flue gases.
It consists in the reduction of NO and NO2 to N2 under the influence of ammonia on the catalyst layer.
• in a second draft
• external reactor
• RETROFIT – low dust DeNOx
• tail end solution
11
SCR System – main components
• Ammonia Storage
• Ammonia Vaporizer
• Ammonia Injection Grid
• Catalyst
• SCR Reactor
12
PROJECT DESCRIPTION:
Design and erection of SCR DENOX plants for 4 coal fired boilers type OP-650k (K7, K8 and
optionally K5, K6) inclusive NH4OH-storage, modernization of rotary air preheater and ID-fans.
MAIN QUANTITIES:
Flue gas flow rate/boiler: 780.000 Nm³/h
NOx reduction (400 mg/Nm³): <100 mg/Nm³, dry 6% O2
NH3 Slip: <4 mg/Nm³, 6% O2
SCR Retrofit Rybnik
Customer: EDF Polska
Commissioning:
March-April 2015 (K7 & K8)
13
NOxCare SNCR system
PU reagent injectionStorageTank
CMM
Combustionchamber /
Boiler
Process control
Reagent mixing & distribution
14
PMR PMW
PMR = Pump module for reagentPMW = Pump module for waterUnloading
pump
ADVANCED TECHNOLOGY FOR POWER BOILER
The Yara SNCR system is designed for high degree of NOx reduction with low NH3 slip and high efficiency of reduction agent
Various Techologies :
� ACL (air cooled lance) – the new injection technology
15
� UDL (urea decomposition lance) –injection of urea betweensuperheaters with no corrosion risk
� CFD model of the boiler / injection of reagent
� Acustic pyrometer or equivalenttechnologies for temperature control in the boiler
UDL
ACL
CASE STUDY (SNCR): COAL FIRED UTILITY BOILER 500 MWel – PILOT PLANTMain information
• Capacity: 500 Mwel
• Maximum continuous rating: 1,675 t/h steam
• Pressure of superheated steam: 178 kg/cm2
• Temp. Superheated steam: 540°C
• Fuel: Coal
• SNCR reagent: urea solution
• NOx baseline: 500 mg/Nm3, @ 6 % O2
16
• Target NOx with SNCR: 30% reduction
• 018
CASE STUDY : COAL FIRED UTILITY BOILER 500 MWel– PILOT PLANT ( NOZZLE’S PLACEMNTS)formation
Vertical urea decompositionlances UDL
17
Horizontal air cooled lances ACL
Globally Prooven Technologyinformation
S.No. Plant Country Units Fuel Eff. of De-NOx system
1 Jiangyin
Ligang Power
China 600 MW Coal- T
fired Boiler
> 30% (SNCR)
2 Martin Lake USA 850 MW Coal
Lignite
> 30% (SNCR)
3 Vindyachal
(Pilot Test)
India 500 MW Coal > 30% (SNCR)
18
(Pilot Test)
4 Rihand
(Pilot Test)
India 500 MW Coal > 30% (SNCR)
Note : *) With Combination of Primary Measures and SCR this reduction can go up-to 90% and we can achieve the MoEfNotification.#) Above references is from different companies (Not only from Yara) to proove the stand that De-NOx is globallyprooven technology
De-NOx – India Power sector
� In Pilot Test, NTPC has limited vendors to only use existing ports and hence there by not able exploit the
complete potential of pilot plant. Nevertheless Yara has been able to achieve an efficiency of approx 30%,
we are however confident that the efficiency can be improved to about 40% if there is flexibity to increase
and decide the ports and their
� SCR pilot plant is an extremely small compared to the full plant hence the actual results of pilot plant may
not be fully representative of the actual results and efficiency that can be achieved, Nevertheless, Yara
has been able to achieve efficiency of approx 90%.
� Tests should be carried out with different reagents i.e Aqua ammonia , Ammonia to be able to ascertain
the most appropriate reagent suitable for Indian
� Flow distribution of high dust gas in pilot set up is more difficult than in full scale plant set-up
� The isokinetic gas sample obtained at the economiser outlet was not provided always the desired
conditions for the SCR reactor. The desired conditions and system control will be more feasible to
achieve for a full scale plant.
19
Nox release at different limits
Typical data for 500 MW Plant
Implication of changing norm from 300 mg/Nm3 to 450 mg/Nm3
Additional NOX in Air per annum 2193 t
Implication of changing norm from 100 mg/Nm3 to 450 mg/Nm3
Additional NOX in Air per annum 3066 t
NOx emissions in India are currently at 9.5 million tons/year. Out of which 55 % is estimated from
total coal firing in electricity generation, heavy and light industry
20
Conclusions
� Globally Proven technologies are available to achieve the emission
norms of <100 mg/Nm3.
� Need better understanding between agencies and Industry for
implementation of the Norms
� Proactive of Power industry , similar to Cement, to implement the
Norms
� Pilot plants should have been built with vendor / industry participation,
involvement and commitment would have been better.
21
� A time bound approach from the regulator will reduce the uncertainity
for all the stake holders.
We are not very far
22