IRRC Waste-to-Energy Conference October 1 st 2 nd, Vienna

Transcription

1 IRRC Waste-to-Energy Conference October 1 st 2 nd, Vienna Improved SNCR Performance by Means of Innovative Control Concepts Dr.-Ing. Wolfgang Schüttenhelm, w.schuettenhelm@wsmaneng.com I 1

2 Contents Introduction SNCR 4.0 Platform Innovative SNCR Control Concepts App Opti-Link Grate Model App NOx raw gas calculation for different grate zones Spray Model App SNCR performance modelling Combination of es Outlook and Summary I 2

3 ERC Emission-Reduzierungs-Concepte GmbH Headquarter: Buchholz i. d. Nordheide / Germany Production Site Additives: Wahlstedt / Germany Associated Companies outside Germany: ERC s. r. o. Prague / Czech Republic ERC sp. z o.o. Szczecin / Poland ERC Chemtrols Ltd. / Mumbai, India ERC Beijing / China I 3

4 ERC Technik GmbH - Products More than 500 DeNO x -References in the Sectors Power, Waste and Biomass Incineration, Cement Industry etc. I 4

5 1. Introduction - DeNOx Technologies for WTE Applications - SNCR Reduction Agent: Urea or Aqueous Ammonia Metering and Mixing e SNCR Injection Levels Temperaturemeasurement 1 Reduktionsmittel 2 Misch und Verteilermodul 3 Wasser 4 Druckluft 5 Verdüsungslanze Storage including Pump Stations SNCR - fit for digitisation? I 5

6 1. Introduction - Driving Forces promoting SCR & SNCR NOx is affecting human health by triggering serious respiratory problems as well as creating the basis of the so-called Summer Smog enhancing ozone generation and it is contributing to acid rain Improving of air quality required world-wide Among others, more stringent emission guidelines for NO x and new - NH 3 were published in Germany for WtE plants: from : 10 mg NH 3 /Nm 3 (daily average) from : 150 mg NO x /Nm 3 (daily average) and 100 mg NO x /Nm 3 (annual average, only new units) for all units > 50 MW th Revision of BREF (Best Available Technologies Reference Emission Values) Tax incentives I 6

7 1. Introduction - Challenges for the Operator of Waste-to-Energy plants Lower legal emission limits are adding to complexity for the operator who should meet all of the following targets at the same time: High throughput of waste avoid part load operation Lower Emissions ideally with safety margin below legal requirements Handle the inhomogeneous waste having different compositions and qualities Long boiler operation time High energy efficiency Low cost of operation, e. g. low cost of utilities and reduction agents Low cost of maintenance and repairs I 7

8 1. Introduction Conflict of Interest Firing Control System (Throughput, Steam / Heat Production, Burnout) Status Firing System No Communication / only one target might be achieved SNCR Control (Target Values, NO x & NH 3 Emissions, Consumables) Status Emissions Fast Data Evaluation? Priority? Advice? Action? I 8

9 2. SNCR 4.0 Platform Process Control System Setting of Target Values SNCR 4.0 Platform Process Data Base & Calculation es Data Communication Additional Monitoring Devices (optional) Visualisation of Results Process Control Room I 9

10 2. SNCR 4.0 Platform Major Development Criteria Data Protection: encoding following the highest safety standards Cloud feature in order to warrant scalability and provide easy updates in future Stand-alone operation without internet connection to operate on local computers Central data base Open system structure & simple interface to integrate future applications Visualisation of collected data by means of a dashboard I 10

11 2. SNCR 4.0 Platform - Architecture Plant k Local Database of the Proxies PDB k SNCR 4.0 Proxy Plant / Unit k fw Synchronisation / Replication of Data Bases < via seriell Interface f w Secured Connection via Network with Authentication (VPN, ssh-tunnel, ) Net? Firewall QoS Management of incoming Data Connections (IP, TCP, VPN,.ssh-tunnel ) fw SNCR 4.0 Service (One or more Servers (Virtual Machines), Load Balancing, Hot-Backup) SNCR 4.0 Scheduler (Synchronisation of s, Monitoring) Starting and (voluntary) scheduling of SNCR 4.0 Functional es, Signaling Online- Balancing Unit k Opti- Link Unit k Grate Model Unit k Spray Model Unit k Prognosi s Tool Unit k Plant K+1 Modbus TCP Separate Network OPC PDB K+1 Separate Network Plant K+2 PDB K+1 SNCR 4.0 Proxy Plant / Unit k+1 fw SNCR 4.0 Proxy Plant / Unit k+2 fw f w f w Net? Net? Networks Authentication, User Administration Synchronisation / Replication (Daemon, Service) SNCR 4.0 PDB Central Data Base fw Online- Balancing Unit k+1 fw Online- Balancing Unit k+2 fw fw fw Opti- Link Unit k+1 Opti- Link Unit k+2 Server Side Code Grate Model Unit k+1 Grate Model Unit k+2 Spray Model Unit k+1 Spray Model Unit k+2 Other es Unit? Prognosi s Tool Unit k+1 Prognosi s Tool Unit k+2 Other es Unit? Fieldbus PDB k Apache es Separate Network PDB k+1 PDB k+2 fw Webserver (Apache) Load Balancing I 11

12 3. Innovative SNCR Control Concepts Opti-Link (Delay of Response!) Stack SNCR + Temperature Measurement Significant Potential of Improvement of SNCR Control: Estimation of NOx Raw Gas Concentration CEMS Measurement: Flue Gas Composition Flue Gas Flow Rate I 12

13 3. Innovative SNCR Control Concepts OPTI-LINK Features Online-calculation of the NO x -Raw Gas Concentration Fast adaption of amount of reduction agent to the variations of the fuel composition Improved performance and / or lower reduction agent consumption Plausibility check of measured values drift detection of measuring devices Online estimation of additional data which are almost impossible to measure (e. g. heating value of fuel, amount of leakage air) but can be calculated by solving mass and energy balance equations Estimation of fuel compostion / fractionation I 13

14 3. Innovative SNCR Control Concepts Opti-Link Fractionation Estimation of Waste Composition including Nitrogen Content by means of Online-Balancing Elementary Analysis Sample Waste Fractionation I 14

15 3. Innovative SNCR Control Concepts Opti-Link Comparison NO x calculated / measured 500 NO x in mg/nm NOx_berechnet calculated Nox-Messung NOx measured :00:00 00:11:31 00:23:02 00:34:34 00:46:05 00:57:36 01:09:07 Time in hh:mm:ss I 15

16 3. Innovative SNCR Control Concepts OPTI-LINK Features Fuel mass flow and calorific value over period of time I 16

17 4. Grate Model App Structure I 17

18 4. Grate Model App Backward Reactor Model Iterative Process Release of CO / CO2, O2, H2O NOx in [g/s] Enthalpy in [W] Total Composition + / - Initial Composition (arbitrary) I 18

19 5. Spray Model App Modeling of Reduction Agent Injection SNCR injection levels Grid model of the furnace section of the SNCR injection levels I 19

20 5. Spray Model App Simulated Reduction Agent Distribution Spray-Calc z-direction [length unit] y-direction [lenth unit] X-Direction [length unit] Flue Gas I 20

21 y-axis [length unit] 5. Spray Model App Modelling of Reduction Agent Injection Initial NOx- Concentration Distribution [mg/nm3] x-axis [length unit] I 21

22 6. Combination of es T- Distribution Spray-Calc e Secondary Air Secondary Air Residence Time Grate e Primary Air Primary Air I 22

23 NOx [mg/nm³ tr. bez auf NO2] 6. Combination of es Calculated NO x Content Primary Zone Zeit in Minuten NOx-Konzentration Grate 1Rost1 NOx-Konzentration Grate 2/3 Roste 2/3 Gesamt-NOx Total NOx Primärzone I 23

24 NOx [mg/nm³ tr. bez auf NO2] 6. Combination of es Calculated NO x Content Secondary Zone Zeit in Minuten NOx Front Wall NOx Furnace Centre NOx Back Wall Total NOx Secondary Air Zone NOx-Konz. Vorderwand NOx-Konz. Kesselmitte NOx-Konz. Rückwand Gesamt-NOx Sekundärluftzone I 24

25 Gesamt-NOx [mg/nm³ tr. bez. auf NO2] Harnstoffdurchfluss [l/h] 6. Combination of es Calculated and Measured NO x Content Vergleich berechnete und gemessene NOx-Gehalte Time Zeit in Minuten Minutes NOx Raw Gas NOx Clean NOx Clean Reduction Agent NOx i. Rohgas berechnet NOx i. Reingas berechnet NOx i. Reingas gemessen Reduktionsmitteldurchfluss Flow Rate Calulated Gas Calulated Gas Measured I 25

26 Summary Increased cost pressure and new emission guidelines are requiring operators to optimise existing plants SNCR has become a serious option to SCR even for higher NO x reduction efficiencies and low NH3 slip Conflicting targets have to be considered in order to achieve the most economical operation of the complete unit For the first time an open and well-structured platform is available as an universal base for monitoring programs. Focus was put on stability, IT security and compatibility as well as expandability. Applying the Apps of the SNCR 4.0 platform results in Better SNCR performance Debottlenecking Capacity increase More flexibility in regards to the waste menu Saving of reduction agent I 26

27 Outlook Validation and improvement of the existing modules Development of further modules (Apps) such as Prognosis module Expert advice module Maintenance module Ongoing development of the vision of communicating plant components both hardware and software Employ the platform s database for analysis and benchmarking purposes looking at the plant or fleet level Use the combination of Opti-Linkt together with the new Grate Model and Spray Model as supportive tools for SNCR design and operation by means of simulating the results of switching single lances depending on the best fit to the raw gas NOx profile. I 27

28 Thank You for your Attention Questions??? Dr.-Ing. Wolfgang Schüttenhelm Tel , I ERC Technik: +49 (0) ERC Technik GmbH, Bäckerstr , Buchholz i. d. Nordheide, Germany 28