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1、07 Sept 200607 Sept 2006The 2nd China InternationalDeSO2 and DeNOx Exhibition & ConferenceSCR Design OptimizationMou Jian, Dr.SCR Design Optimization, M. Jian, Sept 07, 2006Table of ContentslIntroductionlAerodynamic DesignlDuct DesignlReactor and CatalystlAmmonia InjectionlSummarySCR Design Optimiza
2、tion, M. Jian, Sept 07, 2006ALSTOM Environmental Control SystemslEmploys around 1300air pollution controlprofessionalslLocated in 13 countries around the worldlDedicated R&D facilitiesl70 years experience in air pollution controlOur OrganizationSCR Design Optimization, M. Jian, Sept 07, 2006Introduc
3、tionlCombustion TechnologiesLow NOx BurnersOFA/UFAlSNCRlReburning - Gas, Oil, CoallAdvanced Controls - Neural NetslSCRlSCONOxAlstoms DeNOx TechnologiesSCR Design Optimization, M. Jian, Sept 07, 2006IntroductionlFirst full scale SCR operational in 1992l#1 SCR supplier for coal-fired boilers in US30%
4、market sharelSCR ExperiencesFuel types: coal, oil, gas, waste, sludge, bio-fuelDesign experiences: high/medium/low dust, front/ tail endCatalyst: with many worldwide suppliers, on-going R&D test programsAlstoms SCR ExperienceSCR Design Optimization, M. Jian, Sept 07, 2006Introduction - SCRSCR Design
5、 Optimization, M. Jian, Sept 07, 2006Introduction SCRSCR Design Optimization, M. Jian, Sept 07, 2006SCR Design ParameterslImportant SCR Design ParametersSystem aerodynamic designAmmonia inject grid designReactor designCatalyst selection and arrangementSystem pressure dropCatalyst lifeTuning & mainte
6、nanceSCR Design Optimization, M. Jian, Sept 07, 2006Table of ContentslIntroductionlAerodynamic DesignlDuct DesignlReactor and CatalystlAmmonia InjectionlSummarySCR Design Optimization, M. Jian, Sept 07, 2006Aerodynamic DesignlDesign Elements CFD & PhysicalVelocityNOx profileAmmonia profileNH3/NOx mi
7、xingFlue gas temperatureParticulateSCR Design Optimization, M. Jian, Sept 07, 2006NOx Profile - ExampleSCR Design Optimization, M. Jian, Sept 07, 2006Aerodynamic DesignPhysical ModelinglAlstom models every SCR system it supplies SCR Design Optimization, M. Jian, Sept 07, 2006Aerodynamic DesignlFlue
8、Gas Flow Testingphysical & CFD modelsproprietary design standardsextensive field experienceinternal model shoplGas Distribution Devicesproprietary gas mixerturning valves / inlet hoodstraightening vanesuniform temperature, flow, concentrationALSTOMs ExpertiseSCR Design Optimization, M. Jian, Sept 07
9、, 2006Fluid DynamicsCurrent:CV(NH3/NOx)=5.6Optimized:CV(NH3/NOx)=3.1OptimizedOptimised Catalyst Arrangement: A Real ExampleSCR Design Optimization, M. Jian, Sept 07, 2006Table of ContentslIntroductionlAerodynamic DesignlDuct DesignlReactor and CatalystlAmmonia InjectionlSummarySCR Design Optimizatio
10、n, M. Jian, Sept 07, 2006Duct DesignlFlue Gas VelocityDust settinglTurndown RatioNeed to be consideredlSupport SteelDust depositlCorners dead zoneAIG nozzles, damper seat, etc.SCR Design Optimization, M. Jian, Sept 07, 2006Duct DesignlKnowledge of the coal / combustion: clay content, wash, fineness,
11、 comb. additives, etc. lWell considered flue gas duct designlProprietary pop-corn ash collecting device: knock-down separatorlSoot-blowing, screening, etc.Preventing Ash DepositionSCR Design Optimization, M. Jian, Sept 07, 2006Duct DesignNH3/NOx Distribution in the DuctSCR Design Optimization, M. Ji
12、an, Sept 07, 2006Aerodynamic DesignExample of Ash Deposition & ErosionSCR Design Optimization, M. Jian, Sept 07, 2006Table of ContentslIntroductionlAerodynamic DesignlDuct DesignlReactor and CatalystlAmmonia InjectionlSummarySCR Design Optimization, M. Jian, Sept 07, 2006Catalyst & ReactorlDust Load
13、lTemperatureDew pointlPerformanceSO2 conversion, poisons, etc.lEconomicInitial costOperation costSCR Design Optimization, M. Jian, Sept 07, 2006Reactor and CatalystlCatalystsdeactivates with time due to:sinteringpoisoningpore blockagelAmmonia slippage increases as catalyst deactivatesammonium sulfat
14、esCatalyst PoisoningSCR Design Optimization, M. Jian, Sept 07, 2006Catalyst Formulation0.01.02.03.0285295305315325335345355365375Temperature (oC)Relative SO2 OxidationFormulation 2Low ActivityFormulation 1High ActivitySCR Design Optimization, M. Jian, Sept 07, 2006NH3 Slip and Catalyst VolSCR Design
15、 Optimization, M. Jian, Sept 07, 2006Reactor and CatalystReactor Design in Recent US ProjectsSCR Design Optimization, M. Jian, Sept 07, 2006Cost vs DesignThe regression equation isCat, $/mscf = 1.89 - 0.022 SO2 Ox, % +0.000015 CatLife, hrs Predictor Coef SE Coef T PConstant 1.8947 0.9559 1.98 0.061S
16、O2 Ox, -0.0223 0.1416 -0.16 0.877CatLife, 0.00001516 0.00002657 0.57 0.575SCR Temp -0.001100 0.001375 -0.80 0.433S = 0.2364 R-Sq = 12.3% R-Sq(adj) = 0.0%lCost ($) vs Design ParametersSO2 oxidation, catalyst life, SCR temp, etc.SCR Design Optimization, M. Jian, Sept 07, 2006Reactor and CatalystlLow d
17、ust load in the reactor and ductlLong catalyst life, small catalyst pitch, Less catalystlMay require auxiliary heater/heat exchangerTail-end SCRSCR Design Optimization, M. Jian, Sept 07, 2006Table of ContentslIntroductionlAerodynamic DesignlDuct DesignlReactor and CatalystlAmmonia InjectionlSummaryS
18、CR Design Optimization, M. Jian, Sept 07, 2006Ammonia InjectionAIG Design ImprovementSCR Design Optimization, M. Jian, Sept 07, 2006Ammonia InjectionlAmmonia injection is divided into zonesaccording to system characteristicslEach zone is adjusted independentlylBetter suited for heterogeneous flue ga
19、s and NOx profile from the boilerZoned NH3 Injection ControlSCR Design Optimization, M. Jian, Sept 07, 2006Table of ContentslIntroductionlAerodynamic DesignlDuct DesignlReactor and CatalystlAmmonia InjectionlSummarySCR Design Optimization, M. Jian, Sept 07, 2006SummarylReliable system, extensive experienceslOptimized design, customarized solutionslIn-house solutions for plant integrationboiler by-passammonium sulfates at APHID fan integrationlSulfur trioxide controlplume at stacklow oxidationlContinuous ImprovementAlstoms SCR T
