Emerson SCR improves Brandon Shores' efficiency
An
Emerson Process Management product story
Edited by the Engineeringtalk editorial team
May 27, 2009
Constellation Energy has used Emerson's Smartprocess Selective Catalytic Reduction (SCR) optimisation technology to improve the efficiency of its Brandon Shores station.
Smartprocess SCR has improved SCR efficiency and extended SCR regeneration cycles; and reduced nitrogen oxide by 250-tons, which saved USD200,000 (GBP126,578) by eliminating the need to buy additional nitrogen oxide credits.
The Brandon Shores station operates with SCR systems to reduce nitrogen oxide emissions during the annual ozone season from May through September.
The systems work by injecting ammonia into the flue gas to neutralise nitrogen oxide.
For the SCR to work at its target efficiency rate of 90 per cent nitrogen-oxide reduction, the flue gas entering the SCR must be greater than 585F (307.2C).
When the flue gas falls below 585F (307.2C), the ammonia flow-rate drops, resulting in less efficient nitrogen-oxide reduction.
If the flue gas falls below 555F, SCR operation stops completely.
Flue gas temperature is greatly affected by plant load.
Since Brandon Shores participates in the PJM Interconnection market for regulation and is required to closely follow fluctuating load demand, the flue-gas temperature frequently drops below 585F and occasionally drops below 555F.
The original SCR control schemes could not optimise the flue-gas temperature and struggled to maintain the minimum SCR inlet temperature.
Constellation needed an optimisation solution that controlled the SCR inlet temperature more tightly, to meet the SCR efficiency target of 90 per cent nitrogen oxide reduction.
Doing so would help the plant achieve the operational flexibility required to participate in the PJM Interconnection market.
Emerson's solution included revising the original OEM-supplied design philosophy with advanced Ovation control strategies and installing Smartprocess SCR optimisation technology.
Ovation controls the plant's boiler, burner management, data acquisition and flue-gas desulphurisation processes.
Emerson studied the original boiler and SCR designs, as well as associated operational philosophies, and recommended improvements.
Several modifications were implemented in a new Ovation strategy that provided tighter management of the economiser remix temperature throughout the entire load range by revising the control aspects of the economiser bypass and outlet dampers.
This resulted in more consistent control of the SCR inlet and remix temperatures.
The Smartprocess SCR optimisation technology was installed to work in conjunction with the recently modified Ovation controls to further optimise the SCR inlet temperature.
SCR uses fuzzy logic, advanced analytics and model predictive control to closely monitor the system and related data to predict the optimum ammonia usage and current flue-gas composition.
Based on this information it recommended the ideal SCR performance settings.
Smartprocess also automatically calculates optimal bias settings for oxygen, fans and dampers to provide tighter control of the inlet temperature.
Since its installation in 2006, the new Ovation advanced-control strategies and Smartprocess technology have tightened control of the economiser remix and SCR inlet temperatures at higher loads and increased the SCR inlet temperature at lower loads.
The improvement in SCR efficiency has reduced nitrogen-oxide generation, nitrogen-oxide credit purchases and ammonia usage, as well as extended SCR regeneration cycles.
Prior to implementing Emerson's solutions, the Brandon Shores SCR that was tested operated below its targeted 90 per cent nitrogen-oxide reduction-efficiency rate for approximately 190 hours during the ozone season, emitting roughly 650 tons of nitrogen oxide during that time.
After installing new Ovation logic and Smartprocess technology, test results showed that the SCR operated below the 90 per cent target for only 70 hours, emitting 400 tons of nitrogen oxide in this time frame.
By eliminating 120 hours of operation below optimal efficiency, Constellation was able to reduce the amount of nitrogen oxide generated by 250 tons.
At a rate of USD800 per ton, Constellation has saved USD200,000 in nitrogen oxide credits.
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