Catalytic denox management. Minimising the total cost of ownership

Transcription

1 Catalytic denox management Minimising the total cost of ownership

2 Strategic catalytic deno X management can save up to 100,000 a year Dear Reader, We know we are not teaching you anything you don't already know: catalytic deno X systems are costly, and catalysts have to be replaced regularly. But what you may not already be aware of is that the CAPEX and OPEX of deno X systems can still be significantly reduced. This was precisely our goal when we were putting together an end-to-end management approach aimed at controlling the total cost of ownership of such installations. The specific solutions that emerged from this exercise are to be found in this brochure. We hope you will find our presentation interesting. But please don t stop there: feel free to contact us for an in-depth consultation. Our experts can explore with you any opportunities for improvement, evaluating how realistic they are, while bringing all the necessary elements to calculate the gains to be made. We wish you a pleasant read and hope that very soon you will give us the opportunity to turn the talk into action. The essentials Key facts you need to know before reading further Independent assessment could mean catalyst replacement may be deferred. Optimal operation and maintenance increases system efficiency. There are cost-effective alternatives to catalyst replacement, such as regeneration or washing. Less expensive non-oem solutions are available if catalyst replacement cannot be avoided. A comprehensive end-to-end approach Fact finding and lab testing First, we examine the status of the deno X system. By collecting data and running laboratory tests we very accurately determine the exact condition of the asset as well as its remaining lifetime. Case-specific O&M solutions Catalyst solutions Based on these findings we make recommendations to extend the system s lifetime by optimising the operation and maintenance (O&M) conditions. We can also play an active role in putting this advice into practice. CATALYST TEST RESULTS OPERATIONAL DATA SCR asset Performance model VALUES Finally, when the time comes to replace the catalyst, we look for the most cost-effective solution and propose alternatives to standard OEM offers. Our proposal will fit your specific needs and achieve a much lower TCO. DESIGN DATA INSPECTION DATA

3 Why Laborelec is the perfect partner Expert assistance throughout the denox lifecycle ENGIE Lab Laborelec has the knowledge, the experience, the people and the tools to assist customers at every stage of the denox lifecycle: feasibility, design, and operation and maintenance, with reliable advice on non-oem catalyst solutions. 20 years of experience For many years we have assisted in optimising the design, operational performance and maintenance of over 60 catalytic denox installations in Europe, the Middle East, the US and Asia. Our experts are part of an extensive international network of catalyst specialists, including technology providers, manufacturers, user groups, universities and research institutes. Multidisciplinary expertise Experts in combustion, downstream equipment and other disciplines work together to reduce NOX emissions and associated costs. ENGIE Lab Laborelec expertise covers more than denox installations; our skillset enables us to optimise the entire thermal process. Minimum total cost of ownership By improving operating and maintenance conditions, our experts can extend the lifetime, the efficiency and the overall performance of the entire installation. We help minimise the TCO of denox installations, by advising on costeffective alternatives to expensive catalyst replacement, such as guaranteed lifetime extension and OPEX reduction.

4 Is your deno X system in good shape? Assess before you replace Is there potential to extend the lifetime of your catalysts? To answer this question, we need data, so we conduct onsite inspections and run laboratory tests to accurately determine the asset's condition as is as well as its forecast lifetime. From this data we make practical recommendations to enhance the O&M conditions of the deno X installation. Onsite data collection Our experts gather information onsite for further analysis: Visual inspection of reactor and built-in catalysts Collection of design and operational data Sampling catalyst elements Lab testing Samples of the catalyst elements are tested in the laboratory to determine: Catalyst activity SO 2 /SO 3 conversion Pressure drop Chemical and physical composition Assessment Based on the inspection, lab results, and design and operational data, our experts model the deno X system. This model enables us to assess the overall deno X system performance and the remaining lifetime of the catalysts. Benefits Increased staff knowhow: on-the-job training of local personnel and clear explanation of the impact of different O&M parameters on catalyst lifetime. O&M risk mitigation: avoiding unforeseen stoppages due to poor evaluation of catalyst lifetime and degradation mechanisms. Clear budget and maintenance planning: independent assessment of real catalyst lifetime, taking into account the practical considerations of outage schedules and other customer needs. Quantified catalyst lifetime extension: tangible savings achieved by extending catalyst lifetime beyond OEM guarantees.

5 Operations and maintenance make a difference From expert advice to integrated solutions Fine-tuning operation conditions and maintenance practices can help solve operational issues, extend the lifetime and reduce the total cost of ownership of a deno X system. Based on collected data and laboratory testing, ENGIE Lab Laborelec makes recommendations to optimise O&M, and works with local personnel to put these recommendations into practice. Ammonia injection tuning ENGIE Lab Laborelec has the experience and is fully equipped to tune the reagent injection to improve the NH 3 / NO X ratio. As a result, overall deno X system performance improves. Catalyst cleaning systems Our experts provide support for both new and existing systems. We can supply turn-key solutions or assist and train local personnel. Integrated solution Where required, we source and supply specific parts of the catalytic deno X installation (such as emission analysers, local NH 3 lab and large particle ash (LPA) screen), and train local personnel. Benefits Increased staff knowhow: O&M improvements are achieved in collaboration with local personnel, in order to widen understanding in catalytic deno X technology and the sustainability of the optimisation measures. O&M risk mitigation: avoiding unforeseen stoppage and/or higher OPEX due to non-identification. Increased catalyst lifetime: since poor deno X performance can also be the result of poor O&M conditions, replacing the catalyst without tackling the O&M issues is neither sustainable nor cost-effective.

6 Replacing catalysts is complex and expensive Be certain of making the right decision There will come a time when the catalyst itself needs to be replaced. ENGIE Lab Laborelec can assist customers in two ways: providing the suitable catalyst or assisting in the selection of the appropriate original equipment manufacturer. Supply of catalyst solutions Original Equipment Manufacturers are typically keen to offer expensive standard proposals. However, ENGIE Lab Laborelec can offer an alternative catalyst supply proposal that will fit the specific needs of your asset and achieve a lower TCO. Expert assistance during purchasing We assist customers at every step of the purchasing process, from finding the best solution available in the market to technical assistance during negotiations. We develop business cases, consult with the market and evaluate the technical specifications provided by OEMs. Benefits Quantified cost savings: clear and tangible savings compared to standard OEM catalyst proposals. Performance optimisation: technical performance and guarantees optimised for your specific case, leading to a lower TCO. Quality assurance and control: minimisation of performance and financial risks through more secure contractual conditions, complemented by strict quality control and monitoring carried out by our experts.

7 Challenging the monopoly of Original Equipment Manufacturers The market for catalytic deno X systems is typically dominated by the original equipment manufacturers and suppliers, who dictate the maintenance and replacement programmes based on their own, well-protected knowledge of the technology and the equipment. ENGIE Lab Laborelec has resolved to challenge this knowledge monopoly. We are fully independent and our goal is to minimise the total cost of ownership of deno X systems whereas OEMs rely on repairs and replacements to maximise their profit. What sets us apart from OEMs? ENGIE Lab Laborelec Catalyst testing frequency based on asset condition Customised testing programme on a range of catalyst properties, selected depending on asset condition and testing objectives Translation of complex lab results into an overall assessment of the performance of your denox system Catalyst lifetime extension assessment Low total cost of ownership. Independence towards OEMs opens up the possibility of alternatives to expensive catalyst replacement, including: 1. O&M improvement 2. Alternatives to purchasing new catalysts such as regeneration 3. More cost-effective catalyst than that supplied by the OEM Original Equipment Manufacturers High catalyst testing frequency regardless of asset condition Limited standard set of catalyst properties tested under OEM own conditions Delivery of raw and complex test results Verification of the guarantee only High total cost of ownership due to OEM-dictated catalyst replacements Customised catalyst testing programme As catalysts age, their denox efficiency decreases. Therefore, it is necessary to test the catalysts regularly, in order to keep track of their performance. However, testing catalysts is a complex matter. Each type of catalyst has its own testing standard, with more than ten parameters to be tested, and the results depend heavily on the testing conditions. Your advantages We offer a customised testing programme to correspond the needs of your specific system and to translate the results into actionable information. Laborelec is not only a center of technical expertise, but also a renowned laboratory. You can trust the expertise of our test bed and lab experts.

8 Five reasons for you to choose ENGIE Lab Wide range of technical competencies in Electricity Generation, Grids, and End-Use Increased profitability and sustainability of your energy processes and assets Unique combination of contract research and operational assistance Independent advice based on certified laboratory and field analyses all over the world More than 50 years of experience Contact ENGIE Lab Laborelec ENGIE Lab Netherlands ENGIE Lab Latam Rodestraat 125 Amerikalaan 35 Apoquindo 3721, piso Linkebeek 6199 AE Maastricht-Airport Las Condes - Santiago Belgium Netherlands Chile ENGIE Lab Germany ENGIE Lab South East Asia ENGIE Lab Middle East, India & Africa Bromberger Strasse Golden Agri Plaza #05-03 Office 135 FD - Level Wuppertal 108 Pasir Panjang Road Incubator Building - Masdar City Germany Singapore Abu Dhabi, P.O.Box UAE etienne.drouet@engie.com Training needs? laborelecacademy@engie.com