NOx Reduction:

Flue Gas Recirculation vs

Selective Catalytic Reduction
Presented by Jason Jacobi
October 28, 2015
 Agenda

NOx Regulations

What is NOx?

NOx types

How to control NOx?

What is FGR?

What is SCR?

Pros/Cons

CAPEX/OPEX

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 NOx Regulations

Federal
Government
EPA (US)
CCME (Canada)
State/Provincial
Government
California (US)
Alberta (Canada)
Local
Jurisdictions
San Joaquin Valley
(US)
Alberta Environment
(Canada)

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 NOx Regulations
United States

BACT Best Achievable Control Technology

BMACT Boiler Maximum Achievable Control Technology

California & NOx Tolerance:

2 5 mmbtu 30 ppm
6 20 mmbtu 15 ppm
21 75 mmbtu 9 ppm
76+ mmbtu 5 ppm

San Joaquin Valley, CA

20+ mmbtu 5 ppm

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 NOx Regulations
Canada

CCME Canadian Council of Ministers of the Environment

Canada & NOx Tolerance:

40.0 g/GJ (76 ppm) current
13.0 g/GJ (25 ppm) proposed

Alberta Environment
Natural Gas (NG)
26.0 g/GJ (50 ppm) proposed limit
7.9 g/GJ (15 ppm) proposed target

Alternate Gaseous Fuel (AGF)

40.0 g/GJ (76 ppm) proposed limit
15.8 g/GJ (30 ppm) proposed target

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 What Is NOx?

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 Combustion

Fuel
C
S H2
N2
Some
Fuels

- Mixing
Turbulence
- Temperature
- Contact
Time
O2
N2

Air

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 Combustion

Fuel
C Heat
S H2
N2
Some
Fuels

- Mixing
Turbulence CO2
- Temperature H2O
- Contact CO
Time
O2
N2

NO NO2 SO2

Air Emission
Gases
(sometimes)

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 NOx

Mono-Nitrogen Oxides, NO & NO2

NO (Nitric Oxide)
NO2 (Nitrogen Dioxide)
Ambient = Equilibrium
Heat = Endothermic Reaction
NO = 80 90%

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NOx: A Precursor to Photochemical Smog

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 Acid Rain

Nitric Acid, HNO3

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 Three Types of NOx

Fuel
Bound

Prompt

Thermal

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 NOx Formation

Temperature

Duration

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 Total NOx

Result is Total NOx

Natural Gas:
Approx. 120 ppm

#2 Oil:
Approx. 180 ppm
(Fuel Bound Nitrogen .015%)

#6 Oil:
Approx. 425 ppm
(Fuel Bound Nitrogen 0.300%)
Values are based on industrial watertube boilers >100 mmbtu/hr input
Smaller commercial boilers may be capable of lower values

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 Prompt NOx

Forms at lower temperatures

(2200 2500OF)

Reacts with radicals such as

Carbon (C) or Methylene
(CH2)

Minor contributor to overall

NOx production

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 Thermal NOx

2900O F...Nitrogen Oxides

forming (NO & NO2).

Temperature and
residence time.

Major contributor to NOx

production

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 Natural Gas

Primarily Methane CH4

Hydrocarbons
Carbon Dioxide
Nitrogen
Hydrogen Sulfide

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 NOx & Natural Gas

How is it reduced?

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 NOx Reduction

Low NOx Burners

Flue Gas Recirculation

(FGR)

Selective Catalytic
Reduction (SCR)

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 Low-NOx Burners

120 - 80 ppm

80 - 9 ppm

> 9 ppm

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Fitting the Burner to the Furnace

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 Furnace Geometry

Provide the most

generous volume
possible for combustion

Promote more uniform

flame temperature

Elimination of
refractory that re-
radiates heat back into
furnace
Modern Industrial Watertube Furnace

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CFD- Furnace Temperature Profiling

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 S
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 Gas Injection

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26
 Flue Gas Recirculation

120 - 80 ppm

80 - 9 ppm

> 9 ppm

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 FGR
AIR

This is the most popular and

efficient method of utilizing
flue gas recirculation for NOx
reduction.
FGR
Consists of inducing flue
gases using the suction
pressure at the inlet of the
combustion air fan.

TO FD FAN
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 Flue Gas Recirculation

Air Stack

Economizer

Boiler

FD Fan

Burner

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 Flue Gas Recirculation
Cold FGR
Air Stack

Economizer

Mixing
Box Boiler

FD Fan

Burner

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 Flue Gas Recirculation
Cold FGR
Air Stack

OR Economizer
Hot FGR
Mixing
Box Boiler

FD Fan

Burner

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 FGR System Components

Ductwork
FGR
From stack to fan suction Ductwork
Damper
To control % of flue gas
recirculation
Air Inlet Mixing Box
To provide a chamber for fresh
air to mix with flue gases prior to Mixing
burner Box &
Damper
Larger Fan
To handle increased mass flow
and higher mixture temperature
Control Upgrade FD fan
Additional programming,
instrumentation (FGR flow), I/O

Controls

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 FGR

The mixing of cooled flue gases with combustion air effectively

reduces combustion temperature thus reducing thermal NOx.
Using conventional burner technology, reductions of up to 80%
are possible.

Using a 100 MMBTU/hr natural gas register burner as a

reference, typical emissions are as follows:

Uncontrolled: 120 ppm NOx

Using FGR: 20-30 ppm NOx

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 FGR + Excess Air

Sub 20 ppm NOx are possible using induced FGR, but to reach
these levels, the formation of prompt NOx must also be
addressed. This can be accomplished by premixing the fuel and
air/FGR mixture prior to ignition thus minimizing fuel rich zones
which are susceptible to forming prompt NOx.

Using high FGR rates and premixing of fuel and air/FGR, NOx
reductions of 90% are possible thus allowing to reach 9ppm
NOx levels.

These are commonly called Ultra Low-NOx burners.

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As Excess Air Increases, Efficiency Decreases

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 Ultra Low NOx

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 Selective Catalytic Reduction

120 - 80 ppm

80 - 9 ppm

> 9 ppm

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 Post Combustion NOx Reduction

NH3 + NOx = N2 + H2O

SNCR Selective Non-Catalytic Reduction
Spontaneous @ approx. 1800F.
Ammonia injected directly into furnace
Large furnace, adequate residence time
Not practical for packaged boilers

SCR Selective Catalytic Reduction

Lower temperatures @ 600-800F
Ammonia injected at boiler flue gas outlet
Catalyst required
Common on packaged boilers

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 SCR Performance
NH3 + NOx = N2 + H2O

Source testing measurements of NOx & NH3 slip

Usually 90-93% NOx reduction is achieved on units firing NG and #2

oil.

Rule of Thumb : NOx after the Catalyst will be 10% of the upstream
NOx

Ammonia slip is measure at the stack and corresponds to the

amount of NH3 that didnt react with NOx.

Typically NH3 slip levels are of 5 ppm or 10 ppm.

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 SCR Reagent Types
NH3 + NOx = N2 + H2O Anhydrous

Anhydrous NH3
Pure Ammonia liquefied under
pressure
Low capital & operating cost
Perceived as high risk
Can be difficult to permit

Aqueous NH3
Ammonia in 20-30% water
Higher capital & operating cost
Perceived as low risk
Permit normally easy to obtain

Urea
Highest capital & operating cost
Perceived as minimal risk
Permit easy to obtain

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 SCR System Components

Reagent Processing Skid

Anhydrous Ammonia Anhydrous Bottles For Storage, AFCU
Aqueous Ammonia Ammonia Storage Tank, Forwarding Pump
Skid, AFCU c/w Vaporizors
Urea Urea Storage Tank, Urea Conversion Skid, AFCU
Catalyst
NOx Catalyst
Ammonia Injection Grid (AIG)
To inject ammonia
Reactor Housing
Contains precious metal catalyst to assist reaction
System Control Upgrade
Additional programming, instrumentation, I/O

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 System Components
O
N N
H H

O
N N
H H

O
H H

Catalyst
H

H
N
H NO Bed
H
N
O H H
N
O

NO
AIG (ammonia
NO
injection grid)
O
N
O

NO

O
N
O

Ammonia metering and

dilution skid (anhydrous
shown)

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Selective Catalytic Reduction (SCR)

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Selective Catalytic Reduction (SCR)

Ammonia Injection Grid

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Selective Catalytic Reduction (SCR)

SCR Reactor Housing

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 Catalyst

Corrugated Type Single Catalyst

Catalyst Element

Inside the reactor,

catalyst elements are
stacked to form the
catalyst bed.

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 Selective Catalytic Reduction (SCR)

NOx Catalyst CO Catalyst

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 Selective Catalytic Reduction (SCR)

LEFT RIGHT

Anhydrous Ammonia Metering & Dilution Air Skid

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Selective Catalytic Reduction (SCR)

Aqueous Forwarding Pump Skid

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 Selective Catalytic Reduction (SCR)

Aqueous Ammonia Vaporization Skid

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 Ultra Low-NOx Burners

PROS
On-site storage of ammonia is NOT required
No SCR equipment and associated maintenance

CONS
Technology is limited to < 200 mmbtu/hr in a single burner
Burner cost is higher than standard units
Large furnace volumes are required, often resulting in costly
modularized or field-erected boilers at larger heat inputs
Burner turndown is limited (typical 6:1)
High excess air reduces thermal efficiency
High FGR rates increase fan size and power consumption
Complex metered combustion control systems are required
Burner ramp rates are slower than standard systems
Inlet air preheat temps are limited (reduced efficiency)

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 Selective Catalytic Reduction

PROS
Single-digit NOx levels can be achieved
Low cost standard burners can be utilized
Boiler furnace sizing is unaffected
No impact on burner turndown (10:1 typical)
Low excess air does not reduce efficiency
No significant impact on FD Fan power consumption
Burner ramp rates are in excess of 20% / minute
High-temp inlet air preheat systems increase efficiency
More forgiving of fuels with changing compositions
CONS
On-site ammonia storage required.
Increased footprint or height for ductwork
Additional pressure drop across catalyst increases fan hp, but not
significant when compared to ultra low-NOx burners
Catalyst maintenance/replacement required every 3-5 years

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 CAPEX

80,000 lb/hr watertube @ 9 ppm NOx

Item FGR SCR

Standard Boiler $ 960,000 $ 960,000
Add FGR $ 52,000
Add SCR $ 385,000
TOTAL $ 1,012,000 $ 1,345,000
$/lb steam $ 12.65 $ 16.81
33%

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 CAPEX

80,000 lb/hr watertube @ 9 ppm NOx

Item FGR SCR

Standard Boiler $ 960,000 $ 960,000
Add FGR $ 52,000
Add SCR $ 385,000
TOTAL $ 1,012,000 $ 1,345,000
$/lb steam $ 12.65 $ 16.81
33%
SCR costs additional 30%, so FGR is most economical

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 CAPEX

425,000 lb/hr watertube @ 9 ppm NOx

Item FGR SCR

Standard Boiler $ 5,750,000 $ 5,750,000
Add FGR $ 395,000
Add SCR $ 675,000
TOTAL $ 6,145,000 $ 6,425,000
$/lb steam $ 14.46 $ 15.12
5%

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 CAPEX

425,000 lb/hr watertube @ 9 ppm NOx

Item FGR SCR

Standard Boiler $ 5,750,000 $ 5,750,000
Add FGR $ 395,000
Add SCR $ 675,000
TOTAL $ 6,145,000 $ 6,425,000
$/lb steam $ 14.46 $ 15.12
5%
This is interesting.
Cost of FGR vs. SCR is very close.
FGR is $280,000 less.

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 CAPEX

425,000 lb/hr watertube @ 9 ppm NOx

Item FGR SCR

Standard Boiler $ 5,750,000 $ 5,750,000
Add FGR $ 395,000
Add SCR $ 675,000
TOTAL $ 6,145,000 $ 6,425,000
$/lb steam $ 14.46 $ 15.12
5%
This is interesting.
Cost of FGR vs. SCR is very close.
FGR is $280,000 less.

We need to take a closer look at OPEX.

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 OPEX

425,000 lb/hr watertube @ 9 ppm NOx

Item FGR SCR

Increase Fan HP $ 315,539.10 $ 18,254.33 $/yr
Increase NG $ 322,599.70 0 $/yr
Add ammonia $ 235,872.00 $/yr
TOTAL $ 638,138.81 $ 254,126.33

$USD Assumptions:
Electricity: 5/kWh
Fuel Gas: $3/mmbtu
Ammonia: $3/lb (anhydrous)

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 OPEX

425,000 lb/hr watertube @ 9 ppm NOx

Item FGR SCR

Increase Fan HP $ 315,539.10 $ 18,254.33 $/yr
Increase NG $ 322,599.70 0 $/yr
Add ammonia $ 235,872.00 $/yr
TOTAL $ 638,138.81 $ 254,126.33

SCR clearly costs less to operate than FGR.

$384,000 savings per year!

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 Todays Take-A-Ways

1. Our environment is finite and fragile

2. Fuels we burn also finite
3. Efficiency are compromised for ultra low-NOx levels with FGR
4. KWh may also be impacted along with turndown with FGR
5. SCR will not normally impact fuel efficiency
6. Consider ALL options for NOx reduction.

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 Contact Us

Jason Jacobi
Sales Manager
jjacobi@cleaverbrooks.com
402-434-2000
cleaverbrooks.com

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