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NUCLEAR OPPORTUNITY
A Q&A WITH AREVA CEO MIKE RENCHECK
COAL ROUNDTABLE
EXECUTIVES DISCUSS THE FUTURE OF COAL
COAL DUST
HOW TO CONTROL IT
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A Breakthrough re for Clean Coal
July 2013 www.power-eng.com
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OPINION
The Devil Could be in the Details

BY RUSSELL RAY, MANAGING EDITOR
ast month, President Barack Obama officially announced plans to use his executive powers to establish greenhouse gas limits for new and existing power plants in the U.S. The long-awaited announcement contained few details, but it marked the beginning of what will surely be intense negotiations between regulators, environmental groups and utilities. There will be lawsuits, bi-partisan wrangling and a lot of pontificating. Already, the power generation industry has announced plans to retire more than 60 GW of coalfired generation by 2020. Thats about 19 percent of the nations coal-fired capacity. Some of these closures stem from the benefits of low-priced natural gas. But a significant number of these closures stem from a bevy of new rules and standards for mercury emissions, coal ash storage, wastewater treatment and cooling water technology. Establishing the firstever limits on CO2 for new and existing plants will inflate the number of shuttered coal plants in the U.S. But the actual impact of Obamas climate-change plan is almost impossible to measure at this point. It depends on the standard the Environmental Protection Agency (EPA) sets and how the plan is rolled out, said Mac McFarland, chief
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executive officer of Luminant, Texas largest power provider. The devil is in the details and those details will need to be practical and actionable, McFarland told the Dallas Morning News. Its not just the number, but how the reductions over time are achieved. If the CO2 standards for coal plants are based on proven and available technology and the industry is given enough time and flexibility to comply, the vast majority of U.S. coal-fired generation can remain online under Obamas climatechange plan. The Obama-run EPA is expected to release final CO2 limits for new power plants by Sept. 20. A proposal to limit CO2 from existing plants is expected to be issued in June 2014 and finalized by June 2015. The Clean Air Act allows the EPA to set separate standards for each fuel type coal, oil and natural gas. Whats more, the law allows a separate standard based on the best emission reduction technology for each fuel type. Right now, the proposed GHG rule for new plants would establish one standard 1,000 pounds per MWh for gas and coal plants. But this standard can only be met by using one type of fuel natural gas and one type of generating technology
combined cycle. It was written more for a gas plant than a coal plant, said Tim Curran, president of Alstom Power. We believe theyre working on correcting the rule. Something has to change there in order to keep coal in the mix. The rule, in its current form, would likely be tossed out by an appeals court because it fails to provide the flexibility proffered under the Clean Air Act. The EPA is rewriting the rule so it can withstand a legal challenge from coalfired power producers. By law, the EPA cannot finalize CO2 standards for existing plants until it finalizes the proposed standard for new plants. One is inextricably tied to the other under the Clean Air Act. A coal plant would not be able to meet the proposed standard without installing a carbon capture and storage (CCS) system, a risky undertaking due to the cost, liability and questions about CCS technology. The proposed rule seemed to prohibit new coal without any kind of CCS technology. Thats concerning, said Jim Heilbron, senior vice president of Alabama Power. We were happy to participate in those 2 million or so comments that were received. We would suggest that you separate out standards for gas and for coal. That only seems to be appropriate. Obamas climate-change plan will be widely discussed at COAL-GEN 2013, Aug. 14-16, in Charlotte, N.C. To register online, visit www.coal-gen. com. If you have a question or a comment, please contact me at russellr@ pennwell.com.
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CORPORATE HEADQUARTERSPennWell Corp. 1421 South Sheridan Road Tulsa, OK 74112 P.O. Box 1260, Tulsa, OK 74101 Telephone: (918) 835-3161 Fax: (918) 831-9834 E-mail: pe@pennwell.com World Wide Web: http://www.power-eng.com MANAGING EDITOR Russell Ray (918) 832-9368 russellr@pennwell.com ASSOCIATE EDITOR Denver Nicks (918) 832-9214 denvern@pennwell.com ASSOCIATE EDITOR Justin Martino (918) 831-9492 justinm@pennwell.com ON-LINE EDITOR Sharryn Dotson (918) 832-9339 sharrynh@pennwell.com CONTRIBUTING EDITORBrad Buecker CONTRIBUTING EDITORBrian Schimmoller GRAPHIC DESIGNER Deanna Priddy Taylor (918) 832-9378 deannat@pennwell.com SUBSCRIBER SERVICE P.O. Box 3271, Northbrook, IL 60065 Phone: (847) 559-7501 Fax: (847) 291-4816 E-mail: poe@omeda.com MARKETING MANAGER Wendy Lissau (918) 832-9391 wendyl@pennwell.com SENIOR VICE PRESIDENT, NORTH AMERICAN POWER GENERATION GROUP Richard Baker (918) 831-9187 richardb@pennwell.com NATIONAL BRAND MANAGER Rick Huntzicker (770) 578-2688 rickh@pennwell.com
No. 7, July 2013
Looping 12 Chemical for Nearly Zero-
Pollution Coal Power

Researchers at Ohio State University provide Power Engineering an exclusive look into technology that produces power from coal without creating any greenhouse gas emissions.
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Special Report: Coal Executive Roundtable
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Coal Dust Control Boiler Upgrades & Conversions
Opportunity O in Nuclear: A Conversation with Mike Rencheck, President and CEO, AREVA Inc.
CHAIRMAN Frank T. Lauinger PRESIDENT/CEO Robert F. Biolchini CHIEF FINANCIAL OFFICER/SENIOR VICE PRESIDENT Mark C. Wilmoth CIRCULATION MANAGER Linda Thomas PRODUCTION MANAGER Katie Noftsger POWER ENGINEERING, ISSN 0032-5961, USPS 440-980, is published 12 times a year, monthly by PennWell Corp., 1421 S. Sheridan Rd., Tulsa, OK 74112; phone (918) 835-3161. Copyright 2013 by PennWell Corp. (Registered in U.S. Patent Trademark Office). Authorization to photocopy items for internal or personal use, or the internal or personal use of specific clients, is granted by POWER ENGINEERING, ISSN 0032-5961, provided that the appropriate fee is paid directly to Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923 USA 508-750-8400. Prior to photocopying items for educational classroom use, please contact Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923 USA 508-750-8400. Periodicals postage paid at Tulsa, OK and additional mailing offices. Subscription: U.S.A. and possessions, $88 per year; Canada and Mexico, $98 per year; international air mail, $242 per year. Single copies: U.S., $14, Outside U.S. $23. Back issues of POWER ENGINEERING may be purchased at a cost of $14 each in the United States and $16 elsewhere. Copies of back issues are also available on microfilm and microfiche from University Microfilm, a Xerox Co., 300 N. Zeeb Rd., Ann Arbor, MI 48103. Available on LexisNexis, Box 933, Dayton, OH 45402; (800) 227-4908. POSTMASTER: Send change of address, other circulation information to POWER ENGINEERING, PO Box 3271, Northbrook, IL 60065-3271. POWER ENGINEERING is a registered trademark of PennWell Corp. Return undeliverable Canadian addresses to P.O. Box 122, Niagara Falls, ON L2E 6S4. Member American Business Press BPA International PRINTED IN THE U.S.A. GST NO. 126813153 Publications Mail Agreement No. 40052420
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DEPARTMENTS
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Plant Management: Dont Lose Focus on FAC Issues
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Bechtel is among the most respected engineering, project management, and construction companies in the world. Bechtel operates through five global business units that specialize in power generation; civil infrastructure; mining and metals; oil, gas and chemicals; and government services. Since its founding in 1898, Bechtel has worked on more than 22,000 projects in 140 countries on all seven continents. Today, our 53,000 employees team with customers, partners and suppliers on diverse projects in nearly 50 countries. We stand apart for our ability to get the job done rightno matter how big, how complex, or how remote.
CLEARING THE AIR
Planning for the ELG
BY MICHAEL G. KLIDAS, RESEARCH ENGINEER, BABCOCK & WILCOX POWER GENERATION GROUP
ith the U.S. Environmental Protection Agencys (EPA) April 2013 release of the effluent limitation guidelines (ELG) proposed rule regulating wastewater discharges from the steam electric industry, plant owners should investigate their options for compliance prior to the expected release of the final rule in May 2014. The proposed rule will be implemented on a rolling schedule through National Pollutant Discharge Elimination System (NPDES) permits up for renewal and would set limits on the levels of pollutants in wastewater discharge from flue gas desulfurization (FGD) wastewater, discharges from fly ash and bottom ash systems, combustion residual leachate and gasification wastewater. Utilities, however, may want to pay particular attention to the selection of FGD wastewater treatment and the associated interactions with upstream equipment due to the large investment likely needed to comply with the FGD regulations.
ZERO LIQUID DISCHARGE

One strong reason to consider going with a Zero Liquid Discharge (ZLD) option is to avoid potential issues with achieving and maintaining the specified numeric criteria and to avoid additional equipment installations for more stringent future regulations. However, implementation of a ZLD system comes with higher capital and operating costs than some other options. Some facilities may find that the trade-off between the higher capital expenditure and the uncertainty involved with other systems favors ZLD. In the proposed rule, the EPA included a voluntary incentive program to encourage selection of ZLD systems. Plants electing
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ZLD for all of their wastewater streams, with the exception of cooling tower blowdown, could be granted up to five additional years for compliance. This could be an attractive way to postpone the large capital investment of a ZLD system. ZLD system options include evaporation ponds, deep well injection of wastewater, closed loop FGD operation (in which chloride levels are increased and chlorides are purged through gypsum that is landfilled), spray dry evaporation in flue gas and evaporation via mechanical vapor compression (MVC). Since evaporation ponds are limited to deserts and deep well injection requires suitable geologic formations, few plants will be able to select these technologies as a ZLD solution. In addition, if the chlorine content of the coal being burned is high, the closed loop FGD operation may lead to unacceptable chloride concentrations and corrosion concerns . This leaves MVC and spray dry evaporation as the leading candidates for ZLD systems. If a completely closed loop system is beyond the capability of the FGD system due to chloride levels, a smaller increase in chloride level can be achieved by decreasing, instead of removing, the blowdown stream. This offers cost savings for both an MVC system and a spray dryer due to the reduced flow of water to evaporate. This increase in chloride concentration may increase the scaling potential of the absorber tower and/or reduce SO2 removal.
wastewater, concentrated brine is created. This concentrated brine, around five percent of the initial blowdown flow, can be mixed with plant fly ash and landfilled as a solid waste still meeting zero liquid discharge. Partial ZLD avoids operational difficulties that may occur during the crystallization process. This is especially beneficial when softening is avoided leaving predominantly CaCl2 salts in the concentrated brine.
BIOLOGICAL SYSTEMS SOLUTIONS

For those who dont go the ZLD route, there are other options. Due to the NPDES permitting process and the numeric criteria implemented at Merrimack Station, some believe the EPA is leaning towards regulations based on the performance of chemical precipitation followed by biological treatment. Biological systems operate by creating a reducing atmosphere and converting nitrates to nitrogen gas, followed by conversion of selenium compounds to insoluble elemental selenium. Although these systems offer significant cost savings over ZLD systems, potential issues can occur as a result of fluctuating FGD wastewater chemistry. Close monitoring of wastewater will ensure minimal upsets to the biological system and enable suitable living conditions for the reducing bacteria. Whatever solution a utility considers, understanding the interactions between the wastewater technology and the upstream process, using that information to plan viable options, and providing accurate design specifications will help ensure the best available option is selected for each plant.
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PARTIAL ZLD SOLUTION

MVC systems also have the ability to go to a partial ZLD system. For a partial ZLD system, instead of completely crystallizing the dissolved solids in the
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VIEW ON RENEWABLES
Future is Bright as Wind Becomes Mainstream American Energy

BY MICHAEL GOGGIN, AWEA SENIOR INDUSTRY ANALYST
Author Michael Goggin joined AWEA in February 2008. As Senior Electric Industry Analyst, Michael works to promote transmission investment and advance changes in transmission rules and operations to better accommodate wind energy on the power system while maintaining system reliability. Prior to joining AWEA, he worked for two environmental advocacy groups and a consulting frm supporting the U.S. Department of Energys renewable energy programs. Michael holds an undergraduate degree with honors from Harvard University.
snearly10,000windenergy professionals gathered last month for the WINDPOWER2013Conference&Exhibitionin Chicago, there were signs of optimism.Mostindustryparticipantsexpectasignificantdropinwindfarm installationsthisyear,butasolidrecoveryin2014. That forecast follows a very late extensionofthefederalwindenergy production tax credit (PTC). Congressallowedtheincentivetoexpire December31,2012,beforerenewing itthenextday.Theresult:2012was arecordyearwith13,131MWofnew installationsasdevelopersrushedto meet the deadlinewind power accounted for 42 percent of new U.S. generatingcapacity,toppingallother energy sources for the first time. At thesametime,theindustryssupply chain experienced severe whiplash asordersfor2013shranktozeroat manycompanies. With the PTC restored, the industryisreviving.Utilitiesareseizingthe opportunitytopurchasewindpower, which offers both low-cost electricity atlong-termfixedratesandportfolio diversification. Since WINDPOWER, utilityplansforwindtotalingroughly $3.5 billion in investment have been announced: MidAmericanEnergyCo.,owned by billionaire investor Warren Buffett, said it will add up to 1,050 megawatts (MW) of wind generationinIowabytheendof 2015. The new development, it said,willbebuiltatnonetcostto itscustomersandwillhelpstabilizeelectricrates.
XcelEnergyplanstoaddapproximately550MWofnewwindgenerationinColoradobetweennow and2016.Acompanyspokesman said, These projects meet our customersinterestinaclean,reliableanddiverseenergysupply at prices that would make sense for our customers regardless of anyenvironmentalregulations. Portland General Electric said it willbuya267MWwindfarmin Washington state that is under construction and operate it after itscompletedin2015.
SOME HIGHLIGHTS FROM WINDPOWER 2013:

Incoming AWEA Board Chair Gabriel Alonso, of EDP Renewables,outlinedhisvisionofastrategy for the industry to achieve the stabilityandsustainabilityitneeds. That strategy, he said, includes strengtheningAWEAandtheindustrys brand and mobilizing companies and their employees to carry the industrys message to policy makers. Incoming AWEA CEO Tom Kiernan was officially introduced to his new industry. Kiernan said his passion for wind energy is personal: Windpowerisclean,affordable,and homegrown.Thecountryneedsusto succeed. The natural world needs us to succeed. And frankly, my children andyourchildrenneedustosucceed. At another session, representatives of AWEA, the National Wildlife Federation, American Wind Wildlife Institute, and National Audubon Society joinedJoseZayas,directoroftheWind
and Water Power Technologies OfficeattheU.S.DepartmentofEnergy (DOE),tolaunchdiscussionofanew vision for the wind industrys future to succeed the 20 Percent by 2030 technicalreportproducedbyDOEin 2008. According to Lawrence Berkeley National Laboratory, wind energy costs have fallen by one-third over the last several years, due primarily to technological advances yielding larger and taller wind turbines with greater energy production. Utilitiesaretakingadvantageofthese reducedcosts,withatotalof74buyingorowningwindpowerin2012,up from42in2011. Utilitiesandgridoperatorsarealso successfully integrating increasing quantities of wind energy. In 2011, wind energy provided around 20 percent of the electricity in Iowa and South Dakota, and recently broke a newrecordonthemainpowersystem inTexas,providingmorethan35percent of the electricity at one point in early2013. AcrossTexas,theMidwestandparts of the West, new transmission lines thatwillenabledozensofgigawattsof new wind energy development have been approved and are expected to beplacedinserviceoverthenextfive years. Theseareexcitingtimesforthewind industry,andtimesofgreatchallenge as well. Our countrys energy sector mustshapeanewparadigmformeeting Americas energy needs and addressingthethreatofclimatechange. ThebestdaysforAmericanwindpowerarestillahead.
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NUCLEAR REACTIONS
Dark, Spark, and Quark

BY BRIAN SCHIMMOLLER, CONTRIBUTING EDITOR
ts getting tougher and tougher to be a successful nuclear plant these days. Beyond the challenges posed by aging equipment, Fukushima-related upgrades, and the threats posed by renewables and natural gas, nuclear plant profitability is now threatened in some cases by a market metric with a funny name: the quark spread. And while the quark spread is not a causal factor in the travails of nuclear power, its definitely a symptom. The quark spread is the difference between the wholesale price of electricity generated by nuclear power and the price of the fuel (uranium) used to generate that electricity, measured in $/MWh. In effect, quark spread is a proxy for the profitability of a nuclear plant. It is analogous to its more well-known cousins the dark spread and the spark spread which capture the theoretical profitability of coal and natural gas plants, respectively. Dark and spark spreads are terms that have become more familiar in the past decade because coal and gas units have historically been much more likely to be operating on the dispatch margin in wholesale electricity markets. That market condition is now changing. With ample natural gas supplies and low natural gas prices, wholesale electricity prices have fallen, taking quark spreads down with them. As shown in the accompanying graph from the Energy Information Administration (EIA), quark spreads in the Midwest and Mid-Atlantic regions which house a number of nuclear units are getting thinner. There are two main differences between quark spreads and spark and dark spreads, according to the April EIA analysis: Nuclear fuel costs are more stable
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Average Monthly Quark Spreads by Region

90 80 70 $ per megawatt hour 60 50 40 30 20 10 0 2006 2007 2008 2009 2010 2011 2012 2013 Midwest Mid- Atlantic
Jan. 2006 - Mar. 2013 market to recover these costs, and much more exposed to the quark spread. In other cases, the thinning quark may mean considering the pros and cons of operating at least some of the time in a cycling fashion to take advantage of (or respond to) market conditions. These market opportunities may not just be the filling of load valleys caused by varying electricity demand. It also may mean providing ancillary services such as spinning reserve to back up intermittent renewable energy. Taking such actions is not something a nuclear plant would necessarily like to do, but its not something outside the technological envelope, either. Despite their baseload history and reliable baseload performance for decades, many nuclear plants were designed with at least some capacity to cycle. So dont be surprised to see nuclear plant owners dusting off their original design and performance specifications and exploring non-baseload operation.
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than fossil fuel costs. Natural gas, and coal to a lesser extent, experience more short-term volatility than nuclear fuel costs. Nuclear power plant fuel costs are much lower than coal and natural gas fuel costs. In 2011, for example, the coal and gas costs averaged $25/ MWh and $36/MWh, respectively, compared to $6/MWh for nuclear. Given the same wholesale electricity price, therefore, nuclear power plants produce more net revenue. What does the narrowing of the quark spread mean for nuclear plant owners? In some cases, it may impact investment decisions related to major capital expenditures or even decisions such as premature shutdown. Nuclear plants owned by vertically integrated utilities may be in a better position to recover capital investments by passing them through to ratepayers; in contrast, merchant plants are more directly reliant on the wholesale
DEMAND RESPONSE
The Opportunity Gap in Economic Load Response

BY RICHARD FUSCO, REGULATORY AND RESEARCH MANAGER, JOULE ASSETS INC.
ecently, PJM released an analysis, entitled 2012 Economic Demand Response Performance Report, of its implementation of FERC Order 745. Order 745 directed Independent System Operators to create a mechanism for paying a demand response resource the Locational Marginal Price (LMP) at its location for curtailed load whenever the hourly price is above a Net Benefits threshold. In only five months after PJM implemented the order in April 2012, the volume of energy that was curtailed for this program was about equal to the volume that had been curtailed over the previous three and a half years. While this is certainly an achievement, there are still many opportunities to create increased flexibility in PJMs demand side. Since its post-745 rejuvenation, the report shows that Economic Load Response has had more than 42 percent of its participation come from the Dominion zone that stretches from Northern Virginia to North Carolina. The large volume of participation in the zone stems from neither high prices nor populous geography but from the fact that 97 percent of these energy market participants are larger than 5MW. As PJM notes, most participation is coming from a small number of very large customers. Thus, this uptick weve seen in Economic Load Response since last April has been from a couple large industrial customers in remote, uncongested areas of the PJM grid. Additionally, most participation is coming from facilities that are
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responding less to the market and more to the convenience of curtailing, resulting in hours of resource participation with only slight correlation to peak prices. Participants are not taking advantage of the long tail at the high end of the markets price distribution. In fact, the average of the top 1500 hours significantly more hours than participants participated in during the relevant time period in Dominion is still significantly higher than the average price participants made per hour there. It is also worth noting that economic participation is only a small part of demand response in PJM. The report notes that enrollment in Economic Load Response is only 3 percent of the enrollment in Emergency Load Response, a mechanism that allows end-users to bid into the capacity market. The disadvantage to a demand response market dominated by zonal capacity pricing without a robust LMP-based energy market has begun making itself prominent. PJM recently elicited a strong response from several Curtailment Service Providers (CSPs), all of which will now essentially have to fix where their loads are located before bidding into the Base Residual Auction. PJM instituted this because, as they noted in a statement, the current demand response requirements do not provide enough information for PJM to adequately understand the quantity and location of demand response to include in reliability planning. PJMs desire for more locational information about its resources is undoubtedly caused, at least partly,
by the 97 percent of demand side resources that are responding to zonal capacity prices as opposed to granular energy prices. There is currently a significant opportunity gap for Economic Load Response since participation in the program is coming primarily from a few large participants responding mostly as a result of convenience to their own operations. We should focus on enabling more diverse participation through the use of new methods and technologies. This may be utilization of advanced building management systems, facility optimization platforms, two-way communication devices or real time price feeds. It may also include practices such as auto DR and optimized market bidding strategies. Furthermore, we need a variety of endusers at specific LMPs that engage in strategies for participation in a larger quantity of more lucrative hours in order to fully capitalize on Economic Load Response. PJMs implementation of FERC 745 has created greater participation in Economic Load Response. With market barriers removed, we can now focus on tapping into more value on the demand side. By relieving congestion in ways that other types of participants are incapable of, demand side resources have the capability of reaping high revenues at specific times and specific LMPs, which is precisely what Economic Load Response rewards. With optimization of the participation profile, Economic Load Response has the potential to create value that no other market mechanism can.
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At a research-scale combustion unit at Ohio State University, engineers are testing a clean coal technology that harnesses the energy of coal chemically, without burning it. Here, doctoral student Elena Chung (left) and masters student Samuel Bayham (right) display chunks of coal along with pulverized coal (bottle, center) and the iron oxide beads (bottle, right) that enable the chemical reaction. Photo by Jo McCulty, courtesy of Ohio State University.
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Chemical Looping for Nearly
ZERO-Pollution
Coal Power
BY LIANG-SHIH FAN AND ELENA CHUNG, OHIO STATE UNIVERSITY
oal plays a big role in Americas energy present and future. According to the U.S. Energy Information Administration (EIA), coal comprises 20 percent of the primary U.S. energy fuel consumption and provides 42 percent of our countrys electricity generation.1 The EIA projects that coals share of U.S. electricity generation will fall by 2040, but still remain the leader at 35% percent.2 Thus, coal will continue to be important in satisfying growing U.S. energy demands, but how exactly that future plays out will depend a great deal on the development of technologies that eliminate coal emissions. Here in Ohio, coal is used to generate about 78 percent of electricity, according to the Ohio Public Utilities Commission.3 With such a high dependence on coal, Ohio has a long history of pushing innovative technologies that use domestic energy sources while protecting health and the environment. Our lab at Ohio State University is led by Liang-Shih Fan, professor of chemical and biomolecular engineering, who has committed his research career to developing cleaner and more environmentally-friendly fossil fuel conversion solutions. In particular, we focus on applying
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chemical engineering fundamentals in particle technology, gas-solid fluidization and reactor design to develop new chemical process technologies that can address energy and environmental issues. Throughout his career, Fan has continuously researched engineering technologies for pollution control of fossil fuel combustion. Specifically, our group has studied methods for sulfur dioxide (SO 2), nitric oxides (NOx) and toxic metal (arsenic, selenium and mercury) removal from coal-fired power plants. In the early 2000s, we successfully demonstrated clean coal technologies such as the Ohio State Carbonation Ash Reactivation (OSCAR) process for flue gas desulfurization and toxic heavy metal removal and the CARBONOX process for NOx removal from the flue gas using activated coal char. With increasing environmental concern about greenhouse gas emissions from coal-fired power plants, CO2 capture research was a natural evolution for our research, starting in 1998. We began developing technologies for carbon capture, utilization and sequestration (CCUS). This first resulted in the development of the carbonation-calcination reaction (CCR) process for carbon dioxide removal.
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More recently, our chemical looping processes were developed out of Fans lifelong passion of cleaning the environment, protecting public health and providing efficient, affordable energy. We want to continue to push the forefront of clean coal innovations with research in order to secure reliable, domestic energy that has a reduced environmental impact.
CHEMICAL LOOPING
Chemical Looping is an innovative chemical process that converts carbonbased fuels such as coal, biomass, syngas and natural gas to electricity, liquid fuels and/or hydrogen with low to negative net carbon emissions. The process is a series of reduction-oxidation reactions where initially a carbon-based fuel is reacted with metal oxide at high temperatures. The carbon reacts with the oxygen from the metal oxides to form carbon
dioxide and steam. By producing only carbon dioxide and steam gases, the carbon dioxide can be easily separated and captured by condensing the steam. Then using air, the reduced metal particles are re-oxidized back to metal oxides that can be circulated and used again in the chemical looping process. Though todays application of chemical looping is novel, the fundamental concept of the technology started with the steam-iron process in which iron was used to produce hydrogen in the 1900s. Then a similar circulating reaction scheme was used in the 1950s to produce pure carbon dioxide for the beverage industry. The environmental applications of such chemical looping technology were first reported by the Tokyo Institute of Technology in the 1980s. Chemical looping is a type of precombustion and oxy-combustion carbon capture technology where the oxygen
source comes from a metal oxide particle rather than air. Among possible carbon capture technologies listed on the U.S. Department of Energy (DOE)s Carbon Emission Control Technology Roadmap, DOE projects chemical looping to be one of the most economical.4 One crucial advantage of chemical looping is the flexibility in terms of fuel source and products. Chemical looping systems have been demonstrated around the world with both gaseous fuels such as synthesis gas (syngas) and natural gas, or solid fuels such as coal, biomass and waste. The heat generated from such systems can be used for electricity production. This technological process can also be designed to produce hydrogen, syngas, chemicals and liquid fuels. Chemical looping reactors can be redesigned to handle many different types of fuel and to produce a variety of products. In Ohio States Clean Energy Research
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Laboratory, we feel that the simplicity of the chemical looping design is critical; The beauty of the process is the streamlined and flexible design. In place of a conventional pulverized coal-fired boiler, our chemical looping combustion process uses separate reactors to avoid mixing air and fuel, which eliminates the need for costly, energy-intensive gas separation systems. In comparison to other carbon capture technologies, the chemical looping reaction lends itself to higher efficiencies in capturing carbon dioxide. Our patented chemical looping technique is the result of more than 10 years of extensive research from Fan and more than 60 undergraduate students, graduate students and post-doctorates. The lab explores both calcium- and iron-based chemical looping, where the looping media used is calcium oxide and iron oxide, respectively. Two of these processesthe Syngas Chemical Looping (SCL) system and the Coal-Direct Chemical Looping (CDCL) systemhave been progressing closer to commercial scale.
Chemical Looping
Water
Iron Ash Heat and/or Hydrogen
Carbon Dioxide
1
Coal
6
Re-oxidized iron oxides Water and/or Air
1 Pulverized coal is conveyed into the reducer reactor to be reacted with the iron oxide-based particles. 2 Pulverized coal and the iron oxides are reacted at high temperatures, where the coal is combusted to ash and the iron oxides are reduced to iron. 3 A pure stream of carbon dioxide is formed that can be captured. Steam is also formed and removed from the reducer reactor. 4 The reduced iron and ash are transferred to the combustor reactor. Air and/or steam is added to re-oxidize the iron to iron oxides. This oxidation produces heat and/or hydrogen. 5 Ash is removed from the system with a cyclone. Heat and/or hydrogen can be utilized for electricity generation and/or chemical/fuel production. 6 The re-oxidized iron oxide particles are transferred back to the reducer reactor to be re-used and continue the chemical looping process.
Source: Ohio State University
SYNGAS CHEMICAL LOOPING (SCL)

The SCL process utilizes the gaseous fuel-based chemical looping process that converts syngas to hydrogen and heat. As compared to other chemical looping technologies, the SCL system is unique in that it uses three reactors that can allow for co-production of electricity and pure hydrogen. This hydrogen can be utilized economically by the petrochemical and chemical industries. Unlike other chemical looping gasification technologies, our chemical looping systems use a unique counter-current moving bed reducer reactor and fluidized bed combustor reactor. Weve laboratory tested the SCL process for over 100 hours, exhibiting a product stream of pure hydrogen with complete CO2 capture at bench scale (around 2.5-kWth). With this success, we pressed on with a larger scale 25
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kWth sub-pilot unit in Columbus, OH. Over 300 demonstration hours, the SCL sub-pilot unit exhibited above 99 percent purity for CO2 with over 99 percent syngas conversion and 93-99 percent hydrogen purity. With the success at smaller scales, we are now preparing to scale up the technology to a 250 kWth pilot plant
in collaboration with Babcock and Wilcox Power Generation Group (B&W PGG), CONSOL Energy, Inc., Particulate Solid Research, Inc. (PSRI), Clear Skies Consulting LLC (Clear Skies) and Air Products and Chemicals, Inc. (Air Products). This SCL pilot scale is sponsored by the Ohio Department of Development (ODOD) and the U.S.
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The Coal-Direct Chemical Looping sub-pilot demonstration unit at Ohio State University in Columbus, Ohio.
DOEs Advanced Research Programs Agency-Energy (ARPA-E)the agency that specifically helps advance high risk, potentially breakthrough technologies to commercial scale. At the U.S. DOEs National Carbon Capture Center (NCCC), operated by Southern Co. in Wilsonville, Alabama, Ohio States SCL pilot demonstration project will be the largest pressurized scale-up of chemical looping technology for hydrogen generation from coal and biomass. Using a slipstream of syngas from Southerns transport gasifier, the fully integrated 250 kWth pressurized unit will begin commissioning in the third quarter of 2013. This demonstration unit will be used to verify the operability and feasibility of advanced chemical looping technologies. Based on independent economic analyses, both the commercial-scales of the SCL and CDCL technologies are projected to meet the U.S. DOEs goal of less than 35 percent increase in cost of electricity for the production of a new power plant. Further, we anticipate that the commercial scale chemical looping processes can be used for repowering existing coal power plants or for integrating into newly constructed coal power plants.
COAL-DIRECT CHEMICAL LOOPING (CDCL)

Following a similar advancement pathway of the SCL unit, the CDCL sister projectthe solid fuel-based chemical looping combustion system was funded by the U.S. DOE and ODOD. In the CDCL process, finely powdered coal directly reacts with iron oxide beads. Similar to the SCL process, in the first reactor, coal reacts with the oxygen from the iron oxides to form carbon dioxide and steam, which are removed from the system. In the CDCL
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process, the solid iron and coal ash are left behind. One inherent benefit of the CDCL design is that the iron beads can be easily separated from the coal ash because of the size difference. The coal ash is easily removed from the entire system with a cyclone and without the need for any additional fine removal device. Then in the second reactor, the iron beads are re-oxidized to be recycled and reacted with fresh coal powder in the first reactor. Recently, in Columbus and in collaboration with B&W PGG, Clear Skies, and Air Products, we demonstrated the fully integrated chemical looping combustion 25 kWth unit. From more than 600 hours of testing, Ohio State has operated the CDCL sub-pilot system with nearly full conversions of different types of coals while producing over 99 percent pure carbon dioxide. Most recently, the CDCL system completed a milestone by successfully testing a continuous 200 hours test with subbituminous and lignite coals and metallurgical coke. During the CDCL sub-pilot demonstrations, the system produced other pollutants that have been demonstrated to be easily manageable. For example, the process produced
NOx and SO2 concentrations that are comparable to quantities produced from a conventional pulverized coal combustion boiler equipped with a low NOx burner. The NOx concentrations are also typically lower because of the lower reaction temperatures. These NOx and SO2 pollutants can be removed using traditional selective catalytic reduction units and flue gas desulfurization units, respectively. With these successful CDCL demonstrations, Ohio State plans to further scale up with a CDCL pilot scale demonstration unit in the near future with B&W PGG.
FUTURE PLANS AND APPLICATIONS

With the upcoming demonstration at NCCC of the SCL pilot unit, we hope to lead the commercialization of chemical looping technologies. Future testing would require integrating the carbon capture technology with partners for carbon utilization or sequestration. On a commercial scale, the SCL and the CDCL technologies can be implemented as a part of a greenfield plant or as a repowering of the aging fleet of coal-fired boilers in a traditional pulverized coal power plant.
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With the fuel source and product flexibilities of chemical looping technologies, the possibilities for chemical looping are abundant. Currently, we are also exploring a concentrated solar-power-related thermal energy generation technology. As a part of DOEs National Renewable Energy Laboratorys SunShot initiative, Utah State University, B&W PGG and Ohio State are developing asolid-particlesolar receiver thatcan be integrated intoa solar chemical looping process. The recent shale gas boom has also pushed efforts for natural gas conversion technologies. We have demonstrated the viability of using natural gas for carbon capture and chemical synthesis. Ohio State has tested methane at both the bench scale and sub-pilot scale for nearly full natural gas conversion with 100 percent carbon capture. With the
fuel flexibility of the SCL pilot unit at NCCC, we plan to test methane during its operation at in early 2014. Additionally, the chemical looping process can be used to produce various chemicals and liquid fuels. At Ohio State, bench scale tests have also validated the conversion of methane to syngas using the chemical looping technology. We are also researching the application of coal or natural gas chemical looping for gasto-liquids, coal-to-liquids and chemical production. The potentials of chemical looping technologies are extensive, as such conversion processes could be used to generate electricity, to fuel vehicles and to produce useful chemicals with minimal greenhouse gas emissions. We believe that, ultimately, chemical looping is a potentially game-changing technology that can truly make a difference in our energy landscape.
References: 1. U.S. Energy Information Administration, What is the Role of Coal in the United States?: http://www.eia.gov/energy_ in_brief/article/role_coal_us.cfm 2. U.S. Energy Information Administration, Annual Energy Outlook, DOE/EIA0383(2013), May 2013. 3. Public Utilities Commission of Ohio, Where Does Ohios Electricity Come From?: http://www.puco.ohio. g o v/ p u c o / i n d e x .c f m /c o n s u m e rinformation/consumer-topics/wheredoes-ohioe28099s-electricity-comefrom/ 4. Figueroa, J.D., Fout, T., Plasynski, S., McIlvried, H., Srivastava, R.D. Advances in CO2 Capture TechnologyThe U.S. Department Energys Carbon Sequestration Program, International Journal of Greenhouse Gas Control 2008, 2, 9-20.
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complying with a collection of new rules from the Environmental Protection Agency (EPA) . The participants were: Tim Curran, president of Alstom Power; Tom Alley, vice president of Generation, Electric Power Research Institute; and Jim Heilbron, senior vice president and senior production officer, Alabama Power. What follows is a transcript of that discussion. Power Engineering: Together, low natural gas prices and stricter environmental rules are expected to prompt the retirement of more than 60 GW of coal-fired generation in the U.S. by 2020. As a result, plans to build new coal-fired capacity have largely been postponed. Is there enough incentive to pursue projects and initiatives that demonstrate and validate the use of clean coal technologies? How would you describe the progress in clean coal research and development? Tim Curran: I would describe it as stalled. We know that there is substantial work taking place globally on coal. We are on our ninth project of supercritical boilers in India. We recently contracted two 1,000-MW coal-fired units in Malaysia. Were also working on projects in development in Indonesia and Vietnam. Its fortunate that we can keep our competency in this technology working around the world while we hope for a return to the use of coal in the U.S. When we look at the retirements, it seems like, overall, that new gas plants are not moving forward as fast as they had been projected. In terms of new coal and new technology development, were pursuing many options to serve the markets outside the U.S. Tom Alley: I would agree with Tim. I think the pace of any kind of activity around clean coal has certainly slowed significantly. I think the Department of Energy (DOE) is actively funding some
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Difficult Decisions SPECIAL REPORT:

Executives Discuss the Future of Coal-Fired Power
C
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oal-fired power producers are facing a myriad of new rules establishing strict limits on air and water emissions. Whats more, forecasts of abundant gas reserves and low gas prices continue to push the industry further away from coal. As a result, utilities are conceiving calculated strategies that call for a massive retirement of coal-fired generation, hefty investments in new control technologies and a changeover to generation fueled by cleaner-burning gas. Clean coal research and development has slowed, but it has not stopped. Progress is being made on
several fronts. The future of coal-fired generation is still unclear as government regulators work to finalize new rules on greenhouse gas emissions, wastewater standards, and coal ash management. But most agree that coal, which has long been the dominant fuel for power generation in the U.S., will serve a diminishing role in U.S. power production. I recently moderated a roundtable discussion with executives from Alabama Power, the Electric Power Research Institute (EPRI), and Alstom. The discussion centered on the future of coal-fired generation, the sustainability of todays low gas prices and the challenges of
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initiatives around advanced technology on CO2. There are smaller efforts that the industry is pursuing technologies that really manage traditional pollutants. As we do more research on traditional pollutants, we have to continue to look at water. We realize that the technologies weve developed around removing traditional pollutants from flue gas have put those things in some other waste stream. That waste stream ends up being something else the site has to manage. Were trying to stay ahead of the curve in the development of technology around wastewater. Many decisions have already been made. We read announcements every day that plants are being closed. But there are still a number of people out there that are still anguishing over decisions around a particular asset. Do they want to upgrade that asset to include emission controls to comply with current regulations, or is it better to close that asset? Jim Heilbron: As a former wholesale guy, I have to touch on something that Tim talked about, which is the slowdown in the build. I think the economy is a really big player in that. It continues to be sideways, at best, in many markets. Whether it is coal, gas or whatever, it is just slow right now. From a research perspective, there is a lot of advancement in what we would consider a pilot and demonstration scale type of project (at Plant Barry near Mobile, Ala.). We see valuable information coming out of that, which will hopefully lend itself to commercial deployment at some point. Were definitely getting some good information from that project. Were thinking hard about how you reduce the energy-intensive needs of getting CO2 out of the flue gas stream and how to build it cheaper. Those are the two major obstacles that face a CCS retrofit on any existing asset. There are other projects across the country that are in construction phase at the commercial
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scale. We will certainly be paying attention to those and learn as much as we can. You have to think about the economic viability of these projects and how you are going to make them feasible from a customer perspective. When you think about it from a planning perspective, we really need regulatory certainty. Without that, I think CCS development at a commercial scale is challenged because you dont have a regulatory driver moving you down that path. Power Engineering: Power producers have until April 2015 to comply with the Mercury and Air Toxics Standard. Many options are available and several new clean-air rules are still looming. The decisions utilities make now could increase the cost of complying with new limits for other air pollutants down the road. How does a utility avoid choosing the wrong solution? Tom Alley: Every plant is unique. Its an integration of the plant design, the type of coal thats used, access to water. A number of variables go into the performance of the plant and the emissions a plant has. Solutions for emissions control is really a combination of a number of different technologies that are trained together to handle these pollutants. Its not just one technology. Its hard for me to believe that a utility is going to get it wrong. The research and development here is around creating a number of options that utilities have to address the specifics of their plant. All of these things have to be put together in a consolidated form to manage pollutants. So its very unlikely they get it wrong. Its a great role for research and development to work on these individually. That gives the utilities a chance to pick and choose which options make the best sense for them. Jim Heilbron: We have some certainty. We have MATS. We know when
Jim Heilbron
Tim Curran
Tom Alley www.power-eng.com
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that will occur. We have to think about each unit, consider all of the numerous business drivers for that asset, and then decide whether its better to retire or control or retire and replace. Well do that with sensitivity analyses and scenario planning. At the end of the day, you have to go with the lowest cost option thats
best for the customer. We do all that with one goal in mind. How do we comply with the law and how do we deliver the lowest cost, reliable electricity for our customers. Tim Curran: We believe weve got the best portfolio of products to assist our customers. One case and point would
be the development of a multi-pollutant device that we call NID, a semi-dry flue gas desulphurisation system. It enables the customers to meet the requirements of MATS and CAIR with a single device in a most cost-effective way. We developed that device about five years ago, and weve actually demonstrated it in the U.S. Our challenge is to be able to ramp up to support our customers needs with this short time frame to comply. Its tough when you plan for a market and decide youre going to ramp up, but then a scenario changes, which cancels the contract. So were being whipped around as a supplier, but this is our business and were doing all we can to support our customers. Power Engineering: The carbon capture and storage market in North America has suffered several setbacks. Several companies have backed away from plans to add expensive CCS systems to coal-fired plants due to poor economics. Still, a few coal-fired projects under development in North America plan to use CCS technologies. Alabama Powers Plant Barry started capturing CO2 in June 2011 and sequestering the CO2 underground in August 2012 in a successful demonstration project. SaskPowers Boundary Dam project is expected to be completed early in 2014. Mississippi Powers Kemper County coal gasification/ CCS project is expected to be up and running in 2014. In addition, Summit Powers 400-MW coal gasification/CCS plant known as the Texas Clean Energy Project is expected to begin commercial operation late next year. Where is the market for CCS heading? Will the projects at Plant Barry, Boundary Dam, Kemper County and Texas open the door to more CCS projects in North America? Jim Heilbron: We want to keep coal in the mix. We want to have a diverse
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portfolio that can hedge our custom- further the technology and continue the ers risk to price volatility. By keeping use of coal is to have regulatory certainty. all of these fuels alive, were able to We are still doing CCS projects. Three achieve that. As a result, we can deliver years ago, we had 10 projects. Now were the lowest cost option to our customer down to half and all outside the U.S. But at any given time despite what the mar- were still developing the carbon capture ket might be doing in any given com- technologies. We are working with the modity. CCS is really the only technol- government in the U.K. on a 500-MW ogy solution to address the challenge of oxy-combustion demonstration project. large-scale CO2 emissions from fossil It is slow going, but were hopeful that fuel plants. It is definitely technically project will get funded. Were confident feasible. Were proving that in our fleet, the technology will work. and others are too. Tom Alley: The Mountaineer project From a commercial-scale deployment and now Plant Barry certainly demonperspective, we need some regulatory strate the feasibility of using solvents to certainty to give us direction. You have capture CO2. Barry extends that demto be ready to deal with the risk profile of onstration to look at compression, transthese projects, especially when you start port and injection. Theyre beginning to talking about injecting CO2 deep into answer the question about our ability the earth. More work needs to be done to sequester CO2 safely in deep underto give us more ground formacertainty around CCS is really the only tions. These are these projects. I technology solution to very important would tout Mis- address the challenge projects. Theyve sissippi Powers gone very well. of large-scale CO2 Kemper County They show the coal gasification/ emissions from fossil technical feasibilCCS project be- fuel plants. ity of doing some cause it will have of these things. - Jim Heilbron, Alabama Power a much smaller But the market for carbon footprint. It will serve the cus- CO2 becomes very site specific. Theres tomers of Mississippi Power for many plenty of capability for EOR (enhanced years. Its close to 80 percent completion oil recovery), but its very regional. Now and is scheduled to begin operation in youre focusing on other beneficial uses May 2014. Theres proof there that there of CO2. Thats going to be a very chalare CCS options where they are commer- lenging issue to resolve. cially deployable. I have a lot of difficulty looking at the Tim Curran: The fundamental need current projects underway right now is regulatory certainty. We had a dem- and feel that they are opening the door onstration project, AEP Mountaineer, for more projects. I think theyve given that sequestered a similar amount of us a great amount of education. Theyve CO2 as Plant Barrys project. However, accomplished many goals and educated that was stopped because the ratepayers us with regard to parasitic loads and in the areas that plant served would not some of the difficulties associated with pay to continue the project. So with no these projects. But I dont think theyve regulation, AEP pulled the plug because opened the door for additional projects. the ratepayers said no. We also see that Now it will be interesting to watch KemDOE funding is going down, with the per County and Edwardsport to get unpressures on government spending. We derway and watch this technology maexpect a 30 percent reduction in DOE ture. Beyond the projects we see on the funding. We believe the only way to books right now, I dont see a whole lot
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more occurring here in the U.S. I think the market of CO2 is going to be pretty restricted. Power Engineering: The U.S. Environmental Protection Agency has delayed the release of its New Source Performance Standard for power plants. In its current form, the rule would establish one CO2 standard 1,000 pounds per MWh for new plants. Under this standard, it would be almost impossible to build a new coal plant without equipping it with a carbon capture and storage system, a questionable and costly technology. What is the motivation for the delay? Do you think the EPA will rewrite the rule to provide the industry separate CO2 standards for gas and coal plants?
Tim Curran: It certainly appeared, as the rule was written, that it would kill new coal. We along with other industry groups commented on the rule in pointing out that CCS is not currently technically available. It was written more for a gas plant than a coal plant. We believe theyre working on correcting the rule. Something has to change there in order to keep coal in the mix. Jim Heilbron: They havent stated a reason for the delay. But hopefully they went out for comments for a reason. Hopefully theres some more reasonability. I agree with what Tim observed, which was that the proposed rule seemed to prohibit new coal without any kind of CCS technology. Thats concerning. We were happy to participate in those 2 million or so comments that were received. We would suggest
that you separate out standards for gas and for coal. That only seems to be appropriate. Power Engineering: The future of new coal-fired generation depends largely on the price of natural gas. Are todays low gas prices sustainable? Do you have questions or concerns about reserves or pipeline capacity? Tim Curran: We see that supplies are ample, but we also know that gas prices will always be volatile. Whats interesting is the difference in the price of gas here in the U.S. versus Europe. When we look at the global picture, the largest increase in fuel consumption for generation in the last 12 months is coal. We are actively participating in the gas market and are developing the next generation of gas turbines to take advantage of the increasing supply of gas. We are also continuing to develop lower cost CO2 capture technologies for coal combustion, to be ready when the market comes back to being favorable to coal. In general, we dont believe (the price of gas) will stay as low as it is. Tom Alley: Theres a preponderance of opinions. We see the forecasts for $4 to $6 per million Btu for the next five to six years. There seems to be a fair amount of confidence in that. Im fairly confident with what I see on the supply side. The supply picture gets brighter every day. But Im a little concerned about the demand side. Jim Heilbron: Theres no doubt coalfired generation has a lot of pressure on it. One of them is low gas prices. I cant predict it. I look at the same curves. We put them up on overheads and they converge around $4 to $6. We dont see gas as a panacea. We see it as one of the pieces of the puzzle to hedging price volatility on behalf of our customers.
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Dust Control
COAL
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here there is coal, there is coal dust, one of the biggest nuisances for coal-fired power plants. The U.S. produces more than 1 billion tons of coal each year, and more than 90 percent is used to generate electricity at U.S. power plants. Altogether, the nations 1,400 coal-fired units consume more than 900 million tons of coal each
year, according to the Energy Information Administration, the statistical arm of the U.S. Department of Energy. For power plants handling millions of tons of coal a year, minimizing coal dust is a high priority. A wide range of techniques are used to manage, control and prevent coal dust in and around coalfired power plants. Controlling coal dust is vital to worker safety because of the risk of coal dust explosions. In addition to creating safety
and environmental hazards, coal dust increases the cost of maintaining material handling equipment. Many coal-fired plants are turning to high-tech dust suppression systems to control fine airborne coal particles known as fugitive coal dust. From highpowered fans that emit a fine mist of water over large areas to programs that use a combination of anti-oxidants, binders and foaming agents, the technologies vary in scale and cost. A gust of wind can create swirling black clouds of coal dust as coal shipments are loaded and unloaded. These blow-outs may not exceed air-quality standards, but they do create a nuisance for neighboring businesses and homeowners. The suppliers and operators of coal handling equipment are under pressure to provide technologies and develop best practices
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to reduce the nuisance of fugitive coal dust. Coal sealants offer coal-fired plants a way to protect large stockpiles of coal against moisture, oxidation and other forms of deterioration. Left unsealed, coal piles will suffer a loss of Btu value and burn less efficiently. Whats more, it will result in an actual loss of coal.
GE TECHNOLOGY FOR COAL DUST CONTROL

General Electric has developed a new line of products designed to mitigate fuel degradation brought about by oxidation and prevent coal dust emissions. At POWER-GEN International 2012, the company unveiled a portfolio of products known as PowerTreat. GEs PowerTreat technologies allow power plants to control fugitive coal dust without adding excessive amounts of water. In addition, PowerTreat products can help reduce dusting from unloading of coal, by barge or railcar, by up to 90 percent, the company said. PowerTreat also offers effective dust suppression with low moisture addition to the coal, which reduces calorific value penalties and decreases
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For power plants handling millions of tons of coal a year, minimizing coal dust is a high priority. A wide range of techniques are used to manage, control and prevent coal dust in and around coal-fired power plants.
Dustcontrolbindersappliedtocoal senttoshorttermorlong-termstorage. GEs CoalPlus technology retards the oxidation and weathering of low rank coals, which reduces hot spots, smokersandspontaneouscombustion
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coal flow problems that result from wetcoalconditions. As coal plants face challenges to meet or exceed environmental considerations, GEs PowerTreat program gives utilities more fuel consumption flexibilityandtheabilitytoburnchallengingcoal.Thisnewlineofproducts improves the quality of coal, while reducing dust and minimizing hazardous conditions such as spontaneous combustion and hot spots, said John Schumann, general manager of ChemicalandMonitoringSolutions WaterandProcessTechnologiesforGE Power&Water. PowerTreat products, which are a part of GEs CoalPlus portfolio, include: Foaming agents used to provide highexpansion ratiofoamforsuppressingdustattransferpointswhile minimizing moisture addition to thecoal. Anti-oxidantsanddustcontrolbindersappliedtocoalthatisdirectedto short term storage piles to inhibit oxidation of coal while controlling dustthroughagglomerationoffines.
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The DustBoss DB-60 is an oscillating, 25 horse-power fan that can cover 21,000 square feet with a blanket of fine mist. Photo courtesy of Dust Control Technology.
at generating stations. In addition, less weathering reduces Btu losses during outside storage at coal yards and terminals. The CoalPlus portfolio of dust control binders and antioxidants enhances coal quality, reduces dust emissions and minimizes spontaneous combustion, addressing operator safety and environmental compliance, two of the main challenges faced by mines and utilities, said Homero Endara, chemical and monitoring solutions (CMS) senior global product managerwater and process technologies for GE Power & Water.
WATERLESS DUST CONTROL
out with the rest of the swept debris. A majority of the fugitive dust falls into Elgin provides coal-fired power plants the hopper with only a small amount of a waterless dust control system designed dust getting to the filter. to collect fine dust particles without the The Eagle is equipped with a patuse of water. Elgin ented system to pick supplies two types of The nations 1,400 up PM 10 and PM waterless sweepers coal-fired units 2.5 particles. Dry the Waterless Eagle sweeping provides a consume more than and the Waterless number of environ900 million tons of Pelican. mental benefits, inThe Pelican is a coal each year. cluding a reduction three-wheel sweeper. in your water foot- EIA The patented dry print and less silt, a dust control feature includes a dust byproduct of water-based dust control skirting system, dust separator in the sweepers. hopper, and a dust control fan with a maintenance-free filter, working togeth- REDUCING AIRBORNE er to control fugitive dust without the DUST AT UNLOADING use of spray water. A powerful vacuum Other coal dust control technologies fan on the sweeper creates an air stream mitigate dust the same way firefightthrough the debris hopper, conveyor, ers put out a fire. They use a powerful and skirted areas. The inward rushing water spray to smother clouds of dust air carries the airborne dust into the de- erupting from a pile of coal as it is unbris hopper where its allowed to settle loaded in the coal yard.
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The DustBoss DB-60 is an oscillating, 25 horse-power fan that can cover 21,000 square feet with a blanket of fine mist atomized water droplets designed specifically for capturing and containing coal dust. The DB-60 is developed by Illinoisbased Dust Control Technology. We atomize the water to 50-200 microns, which gives us the maximum attraction and avoids a slipstream effect, said DCT President Edwin Peterson. The DB-60 features 30 brass nozzles designed specifically to atomize droplets to the optimum size for dust capture. The dust suppression system is used at a coal-fired plant in Oahu, Hawaii. The owner, AES Hawaii, was using sprinklers and hoses to control the dust and was looking for a more efficient system. The company rented a DB-60 unit and consequently purchased the machine from DCT, according to DCTs website.
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Nationwide Boiler Inc. has been working with many customers who are choosing to replace their boiler systems with a natural gas-fired boiler system.
Boiler Upgrades and Conversions
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BY JUSTIN MARTINO, ASSOCIATE EDITOR
he phrase boiler upgrade might call to mind images of increasing a boilers efficiency or output. While that does make up a portion of the current boiler upgrade work, the main drivers for boiler upgrades currently are very different. The primary influence would probably be the cost of fuel, because thats always the long-term cost of a boiler system, said American Boiler
Manufacturers Association President Randy Rawson. For those users that are fueled by oil, theyre looking to go to natural gas if they can in their localities. For those fueled by coal, theyre probably looking to do the same thing. The second driver for boiler upgrades is environmental regulations, Rawson said, especially for owners of industrial boilers looking to comply with the Industrial Boiler Maximum Achievable Control Technology
Standard. The Industrial Boiler MACT is probably right now the largest driver in that segment simply because its the newest, Rawson said. There are other local rules and standards in various areas of the country that have provided challenges to boiler owners, but clearly not to the degree the Industrial Boiler MACT probably has. The new Industrial Boiler MACT rules lean heavily on energy assessments and boiler tune-ups. Rawson said those are both good areas to look not only for meeting the standards of the rule, but also to ensure a boiler is running efficiently or effectively. The focus of the rules also means some operators may not need to make many changes in their boiler room. If youre lucky enough to have an up-to-date, state-of-the-art boiler room, youre not going to have to do much upgrading, he said. If you havent operated and maintained the boiler room in accordance with OEM (original equipment manufacturer) recommendations, then you may have to do some tweaking. And depending on the boilers age, tweaking may be easy or difficult. Some companies who find it difficult to tweak their boiler into compliance with the rule may find it easier to convert to a natural-gas fired boiler. While an oil-fired burner may be able to be converted to fire natural-gas, a boiler that fires solid fuel, such as coal, may need to be replaced completely. If youre burning coal, and I think the boiler MACT gets to the coal user more than anyone else, youre going to
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have to take a good, hard look at what you need to do to upgrade, Rawson said. Joe Baranski, lead engineer at Day & Zimmermann, said the company is working with many customers that have already made the decision to switch from their current fuel to natural gas. Switching to a natural gas-fired boiler can involve many changes in the boiler and the facility itself, he said. Plants that are running boilers using solid fuels such as coal currently have to offload the fuel in bulk, Baranski said. The coal could be delivered by truck, although large boilers might have coal delivered by train.
The bulk unloading of coal would be removed from the equation, he said. That includes the storage where coal is held in inventory, the system
Depending on the boilers age, tweaking may be easy or difficult.

- Randy Rawson, ABMA
used to convey coal to the boiler and bunkers that hold a supply of coal above a pulverizer, if that is being used in the boiler. All of these components need to be
abandoned in place after theyre made safe, or they can be removed from service entirely and either sold for scrap or sold on the open market, depending on the condition of the component, he said. In addition, the windboxes and burners would also need modification, Baranski said, and may be removed entirely and rebuilt. Depending on the size and complexity of the burners, as well as what is available from the original equipment manufacturer, certain portions or components could be rebuilt and replaced. Flame scanners in the boiler would need to be removed and replaced for
Tennessee Valley Authority will be adding scrubbers and selective catalytic reduction systems to its Gallatin coalfired power plant by the end of 2017 to reduce emissions.
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TO THE RESCUE
Nationwide Boiler has worked with many clients seeking to replace their current boiler system with a natural gas-fired boiler, including this boiler that was installed at Duke University.
natural gas. When that is done, the owner has the option to upgrade the boiler to lower nitrogen oxide (NOx) emissions. The OEMs and the burner subsuppliers have made great advances in low NOx burner technology, Baranski said. These can be accommodated in the new windbox. On the downstream side of the system, Baranski said there are a few changes that can be made. The scrubber, precipitator, fabric filter (or baghouse) and carbon injection system for mercury removal can be removed from service or isolated. In addition, the gas pass to the stack can possibly
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be readjusted to reduce pressure losses in the gas side, which would result in a cost savings. Its also possible that some of the components within the heat transfer surfaces of the boiler would have to be changed, he added. The characteristics of the combustion of natural gas are different from coal, especially with the pulverized coal often used by the boilers Day & Zimmermann work with. More of the heat release and heat recovery with coal occurs inside the furnace, where water walls will take up a large portion of the radiant energy, while in natural gas combustion, more of the radiant energy occurs in the back end of the boiler. There are a lot of elements to be considered in making the transition, Baranski said. Those elements can become more complex when dealing with larger boilers, such as those that might be used by a utility power station. While most small boilers may only use one or two burners, large boilers may use
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multiple burners. Once you get to multiple burners, there are lots of permutations on how you would fire those burners to meet a given steam demand, he said. And if you have multiple burners that need to be fired, the fuel-air ratio control system is also increased in complexity. The downtime to convert a boiler to natural gas can vary depending on the size of the boiler, though the general rule of thumb is six months to a year. Baranski said one client the company worked with had excellent controls on an integrated engineering and construction schedule and was able to trim time off that. The key to reducing the amount of time a boiler would need to be down is doing as much work ahead of the shutdown as possible, he added. Another method to prevention disruption to the facility is to arrange for a different source of power to avoid a shutdown. Our clients who have smaller installations or smaller developed sites are able to use rental boilers to
The choice is to clean up the coal or make the transition over to a natural gas fuel.
- Joe Baranski, Day & Zimmermann
complement their infrastructure so the interruption for steam generation is minimalized, Baranski said. In that case, what I loosely refer to as prework can be included prior to the shutdown of the rental boiler. You wouldnt notice the difference because the steam would keep coming. Despite the complexity and the possible need for a shutdown, there are many reasons companies may choose to convert their current boiler system
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to firing natural gas. The price of natural gas is attractive to many of Day & Zimmermanns clients, Baranski said. Other factors include the ease of using gas compared to a fuel like coal and environmental regulations that put more of a burden on coal-fired power generation than gas-fired power generation.
fabric structures
A lot of people are running to gas for a lot of reasons. Coal is going away.
- Tim Martin, Nationwide Boiler
The choice is to clean up the coal or make the transition over to a natural gas fuel, he said. Tim McBride, sales engineer at Nationwide Boiler Inc., said emission controls are less of an issue for companies with natural gas-fired burners. Although some states such as California may require more stringent environmental controls, most new natural gas-fired boilers are able to meet environmental regulations without major upgrades. Like Baranski, McBride said he has seen many companies choosing to convert to a natural gas-fired boiler. A lot of people are running to gas for a lot of reasons, he said. Coal is going away. For some operators, however, switching to natural gas may not be the best option. Mark Minniti, NAES Corp. director of business development for the maintenance and construction group, said there are a variety of factors to consider before making a switch. I believe it is a mix based on many factors, such as geographic location, number of other plants in the generators system, the generators current fuel diversity, anticipated capacity requirement, age and size
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of the units, the cost to add control, whether the generator is regulated or unregulated and politics in the state, region or locale, he said. A number of different controls can be fitted onto a boiler system in order to reduce the emissions of the unit. Fluegas desulfurization, selective catalytic reduction, active carbon injection and dry sorbent injection technology can all be added to a plants emission system. Other options include a new fabric filter or adding or upgrading electrostatic precipitators. All of these options are used to help control the amount of emissions from a boiler, including sulfur oxides, nitrogen oxides, carbon dioxide, mercury and particulate matter. Deciding which options are needed may make the situation more complicated, however. Minniti said
many companies are waiting for government agencies to finalize the regulations, then researching the available options and comparing the effectiveness and costs relative to other options. Regardless of what a boiler owner chooses to do to upgrade their boiler, Rawson said its important companies make decisions quickly in order to help control cost and the time it would take to do the necessary work. Regardless of what is motivating you to retrofit, upgrade or replace, the longer you wait, the more expensive its going to be, he said. I dont think anybody can make that determination easily, but they need to be very careful because sooner or later when they knock on our doors there are going to be delays and the costs will have gone up farther than they are today.
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nuclear industry that has led to where he is today: president and chief executive officer of AREVA Inc., a leader in one of the most dynamic and future-oriented industries on earth. Power Engineering: What is the AREVA Solutions Complex and why is it important? Mike Rencheck: The AREVA Solutions Complex is basically an innovation center. Its a collection of areas where we produce technologies to make the nuclear fleet safer, more reliable and more economical. For nuclear applications, we have a 7-GHz, ten-thousand pound shaker table. Its one of the largest, if not the largest, in this hemisphere. We have ovens to commercially test equipment. We have other environmental chambers. We have metallurgical labs and a full chemistry lab. We have one of two electron microscopes in the world there, where we can turn the electron beam on a piece of either contaminated or noncontaminated metal and it will tell you the chemical composition of the metal; then you can start to peel back the grain boundaries. We have machine shops, refurbishment areas, a motor area and a fuel inspection area, plus classrooms. We can even do electrical component reverse engineering. We set this complex up so that we could continue to keep the existing fleet running, looking at plant life extensions to eighty yearswe have all the tools available to analyze an existing plant system and make sure it is capable of running for 80 years. Were also developing repair techniques and inspection techniques, which we are deploying. Its a unique facility in the industry and we think it will help the existing fleet of nuclear plants stay in business. Power Engineering: Where do you see AREVAs future in North America? Mike Rencheck: AREVA is vertically integrated across the entire nuclear footprint, so we have mining, enrichment,
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Mike Rencheck, President & CEO, AREVA Inc.
Opportunity in Nuclear A Conversation with Mike Rencheck,

President & CEO, AREVA Inc.
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BY DENVER NICKS, ASSOCIATE EDITOR
hile Mike Rencheck was finishing up a degree in electrical engineering at Ohio State University there was trouble back home in Pittsburg, where the closure of a steel mill sent his familys finances into a tailspin. The entire family lost their jobs in a matter of about six monthsbrother-in-laws, cousins,
unclesit was pretty devastating, he says today, his irrepressible smile tinged with a hint of solemnity around what was clearly a serious event. I was asked by my parents to come back home to help out. Fortunately, hed been a summer intern at the Beaver Valley Power Station, near Pittsburg, back when its Unit 2 reactor was still under construction. After finishing school he was offered a job at the plant, and so began a career in the
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we make fuel assemblies, service existing plants and we build new reactors. We have reactor designs that start with the EPR at 1,600 MW. We also have a boiling water reactor, KERENA, at 1,200 MW; the ATMEA, which was just selected for use in Turkey, is a 1,100 MW pressurized water reactor, and we have small reactors. Here in North America, our high-temperature gas reactor design has been selected by the Next Generation Nuclear Plant Alliance, and were involved with several companies developing small modular reactors. So we have a full product range offered by reactors and services group. We also specialize in keeping the existing fleet running and are one of the innovators in license renewal. We also have a back-end division, which basically does dry-cask storage, as well as technologies for decommissioning and recycling. And last but not leastour front-end division has a fuel plant in Richland, Washington, where we make both boiling water reactor and pressurized water reactor fuel. Were capable of making many other styles of fuel there as well. Were also pursuing the Eagle Rock Enrichment Facility in Idaho; we already have a license for the facility from the Nuclear Regulatory Commission, and were working to find an investor for the early years and are still in discussions with the Department of Energy for a loan guarantee. Power Engineering: Whats the climate for nuclear build or nuclear activities in general in the U.S.? Mike Rencheck: There are a few things that electric utilities need to factor in. One is fuel diversity. If we start focusing on one source of fuel, such as natural gas, well be setting ourselves up for failure at some point in the future. Now whats causing that sentiment is probably a better question. When you look at whats happening in the economy right now, its low energy demand that is driving pricing to a point where, whether its a new gas plant, coal plant, nuclear plant, solar plant, wind plant, that price isnt
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high enough to send a signal to build new generating plants. Its also not high enough to cover both the operating cost and in some cases the capital investment costs to keep some of the facilities operating, be they gas, coal, or nuclear. How long will this last? If it lasts too long well see decisions made around short-term profitability, especially for investor-owned utilities in the marketplace. So we could be in for the perfect storm where we retire too much capacity in the near-term because of market pricing signals and some market distortions due to weak demand. Then, when the economy recovers and the electricity markets pick up, we find ourselves in an upside-down position, with real electricity shortages and the need to build capacity fast. That could force us in a direction of very volatile fuel sources, typically fossil fuel sources. Power Engineering: What about the prospect for something like a carbon tax? Mike Rencheck: A carbon tax would have a big impact on how nuclear is viewed within the industry. It would send a signal for cleaner forms of generation. However, with energy demand down as a whole, unless the tax is very high, it would not likely be enough to stimulate new build. So youre looking at a merchant market condition that is somewhat tenuous. The Electric Reliability Council of Texas (ERCOT) is a perfect example of that right now. If you watch ERCOT and how theyre going about dealing with capacity shortages or potential capacity shortages, you see a marketplace that is struggling to add new sources of generation, time and time again, without the proper price signals. Power Engineering: What do you look for in hiring people? Mike Rencheck: Theres a lot to be said about how one behaves as a leader. One, you have to be willing to make
decisions, sometimes very difficult ones. Other times, you have to be the kind face, the gentle face, to make sure that people are inspired and motivated to do new things. You have to be creative. You have to be willing to take risks and understand that those risks are manageable, and you have to be able to help folks manage risks. There are a lot of people, especially in the engineering world, that are risk-adverse, but true innovation wont happen without taking some risks. So, as a leader, you have to make it okay for that to happen, because you fail nine times before you find the one true success thats going to help the industry. So, when we look for leaders within a region were looking for people with people skills, with the ability to both take a risk, be kind and gentle, and at the same time be firm and make decisions when needed. Were looking for these people as they come through the ranks, to help shape the next generation of leaders here within the industry and within our company. When you look at the top fifty innovative companies in the world, AREVA is ranked number thirty-eight, and we view that as a responsibility in the industry. Nuclear is our business. Without nuclear we have very little business, although now were getting into renewables and also medical isotopes. Its a tough business in that you have to have high standards, be able to articulate those standards, and have others adopt and follow those high standards while keeping everything in balance. This industry is all about safety and for us, when we innovate, that has to be first and foremost. We always say we start with excellence in mind, and then we frame everything around safety, quality, high performance, and delivering results. Power Engineering: Prospects for nuclear fusion power? Mike Rencheck: On a global basis, were part of the ITER team. Were working on the cooling systems and have a
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very keen interest in whats happening in California at the Lawrence Livermore National Lab (LLNL) where fusion is being tested in the U.S. Weve had a number of people visit and really take a good hard look at what theyre doing at LLNL, and they seem to be making progress. Fusion is probably still out there in the future, but we have folks that are actively working on different projects for it. Power Engineering: You mentioned theres another Mike Rencheck in the world who may go into the nuclear fieldyour son. How do you feel about prospects for his career should he go into nuclear power? Mike Rencheck: I think theyre very good. One of the things the nuclear industry gives you is it really teaches you how to lead people and how to manage in times and circumstances that require
innovation and creativity, high standards for safety, performance, and at the same time it requires you to manage the financial aspects, public interface points . I think when you enter this industry at a young age, you learn how to do these things, including project management skills. I wasnt in nuclear my entire career. I left nuclear around 2001 went into traditional generation including environmental controls on power plants, maintenance and related aspects. I found that the skill set I had learned in nuclear or around management of facilities directly applied in that space. We didnt need all the regulatory paperwork and its burdens, but the techniques of the management ideas all fit very well. We saw great improvements in terms of fossil plant outage durations, construction times, the ability to build large facilities in a very orderly manner. So as my son
considers joining the nuclear industry, I think as a young engineer coming out of college, hell have that same opportunity. So should he, when he graduates, decide to become a nuclear engineer or work nuclear power, I would be very happy with that. Power Engineering: Anything else? Mike Rencheck: I think nuclear will offer the opportunity for jobs, not only in the near-term, but in the long-term. When you look at whats happening right now within the industry, youll see the national demographic shift where we have roughly seventy million boomers and thirty million gen-Xers take place. In nuclear, a very highly technical field, youll see the number of job openings swell. What you see happening now with children as theyre moving through grade school, the ninth grade has about four million or so students, and when you get
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to the point of graduating from college, youre down to roughly a 170,000 students that will graduate with a science, technology, engineering or math (STEM) degree. So think about those demographics, think about the job opportunities in that space. Ive read different articles that say by 2018 therell be a million job openings for STEM positions. Power Engineering: The Nuclear Energy Institute says by 2016 maybe as much as thirty-nine percent of the nuclear work force will enter retirement age. Mike Rencheck: Ive seen statistics for companies our size where the number of employees over 60 equals 20 to 25 percent of the company and thats not unique. You talked about my son specifically, but when you look at that from a population perspective, if you want a job and you want a good paying job, nuclear offers that opportunity. Our starting salary is pretty high and thats for folks with and without a college degree. So if you get into a technical field and go work in the AREVA Solutions Complex, working on qualifying equipment or components, thats a pretty high-paying salary, especially in Lynchburg, where you dont have the cost of living of a place like Washington, D.C. The industry is safe. There havent been any fatalities in the industry as a result of a nuclear accident. Theyre good jobs. Theyre not just short-term jobs. You can build a career in this industry. You can go to work like myself at the age of twenty as an intern, and thirty years later, you have a career to look back on. And if you choose to leave it, the skill sets that you attain are applicable elsewhere. I think in the near-term, if youre talking about opportunity, with the Boomers retiring and the need for energy always alive, youre seeing vast employment opportunities in the energy field that often go overlooked. Nuclear power has a safety accident rating from OSHA (Occupational Safety and Health Administration) of 0.06 reportable events per 200,000 hours worked. The financial industry has a higher accident rate. Think about that. Manufacturing as a whole is 4.4. That stunned me, because when I look at that, for our paradigm that would be completely unacceptable. Its just the opportunity, the genuine standards and skill sets that you get taught and safety that you can apply in any industry. If you look at Alcoas financial turn-around years ago by Paul ONeill, he focused on one thing: safety. He would talk about safety in front of Wall Street analysts. Theyd want to talk about numbers and hed want to talk about safety and what happened to the performance of that company? It just took off. Its those value systems, those leadership traits, those management traits, that set you in a good way whether you decide to stay in the industry or not. I think that these leadership traits are unique to this industry. For info. http://powereng.hotims.com RS# 29
www.power-eng.com
NOx & SOx as Piec of an Overall Emissio
Control Puzzle
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BY KEVIN CRAPSEY, VICE PRESIDENT OF CORPORATE STRATEGY AND DEVELOPMENT, ECO POWER SOLUTIONS
ince the passage of the Clean Air Act, fossil-fired power generators have fueled a robust market for technologies to address nitrogen oxides (NOx) and sulfur oxides (SOx) emissions. The industry estimated in 2009 that it had spent $75 billion to comply with the Clean Air Interstate Rule alone. A number of different technologies have succeeded in addressing one or both of these pollutants, including flue gas desulfurizers (FGDs), selective catalytic
reduction (SCR), selective non-catalytic reduction (SNCR) and sorbents (materials used to absorb gases and liquids). While this market addressed the needs of power generators in the early 1990s, it may be time to consider the needs of 2013 and beyond. As the Electric Power Research Institute (EPRI) noted under its Integrated Environmental Controls program (Program 75), fossil fuel-burning power plants also need lower-cost and better-performing sorbents and technologies than those currently available.
One of key reasons to review emissions control options is that NOx and SOx are not the only pollutants that are regulated. Gas and coal power generation plants must address emissions to remain competitive due to additional regulations by the Environmental Protection Agency (EPA). The introductions of the Mercury and Air Toxics Standards (MATS) and upgrades to the Maximum Achievable Control Technology (MACT) rules need to be tied into NOx and SOx control strategies. Traditional emission control
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Eco Power Solutions operates two of its systems one on gas-fired boiler and the other for coal-fired - at their technology center in Louisville, Ky. Photo courtesy of Eco Power Solutions.
been documented capturing NOx and SOx as well as many other regulated emissions - with one system, less costs and, generally, less space. Also, many of these systems capture greater amounts of NOx and SOx than traditional technologies, can be modified to accommodate predicted future emissions restrictions and can be installed in comparably short amounts of time.
CURRENT NOx AND SOx CONTROL OPTIONS

Traditional flue gas desulfurizer (FGD) systems are built for the express purpose of removing SOx from the exhaust flue gases of fossil-fuel power plants and sometimes from the emissions of other SOx emitting industrial processes. These systems generally employ five removal methods: Wet scrubbing that uses alkaline sorbent or seawater to scrub the flue gas; The spray-dry scrubbing that uses similar sorbent slurries; Wet sulfuric acid process that recovers sulfur in the form of sulfuric acid; SNOX Flue gas desulfurization that removes sulfur dioxide, nitrogen oxides and particulates from flue gases; And dry sorbent injection systems. FGDs employ two stages: one to remove fly ash and the other to remove SOx. In wet scrubbing systems, the flue gas passes through a fly ash removal device, either an electrostatic precipitator or a wet scrubber, and then into the SOxabsorber. In dry injection or spray drying operations, the SOx reacted first with the sorbent, and then the flue gas passes through a particulate control device. These devices have been applied to combustion units firing coal and oil from
ces ons
technologies only capture one or two pollutants at a time, meaning that addressing the full complement of regulated emissions requires capital expenses for multiple technologies and excess space to install. The lack of technological options to comply with EPA regulations has resulted in uncertainty among power plant operators about the ability to meet deadlines and deliver cost-effective electricity. The emission control industry, however, has introduced some advanced systems that may solve this problem. Multipollutant emissions control systems have
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5MW to 1500MW. Approximately 85 percent of FGDs units installed in the United States are wet scrubbers, 12 percent are spray dry systems (similar to dry injection systems) and 3 percent are dry injection systems. On average, web scrubbers achieve the highest SOx removal rates above 90 percent - and dry injection systems achieve the lowest below 80 percent. The choice between the two is often dependent on costs and the nature of the power generation facility. With selective catalytic reduction (SCR) systems, flue gas is first treated with a reactant, which oxidizes it, and then is absorbed into a catalyst. These catalysts are manufactured from various ceramic materials, which are used as carriers, and active catalytic components that are either oxides of base metals, like vanadium or tungsten, zeolites or precious metals. Naturally, each catalyst component that makes up an individual catalyst has its advantages and disadvantages, so component selection is often tailored to the nature of each facility and mix of gases that will be absorbed. Commercial SCR systems generally reduce the level of NOx by 70 to 95 percent and can be found on large utility boilers, industrial boilers and municipal solid waste boilers. These systems have their limitations. SCR systems have been documented as sensitive to contamination and plugging during normal, and abnormal, operations. The pores of the catalyst are easily plugged by a variety of compounds present in ordinary flue gas and certain pollutants can render the system ineffective at NOx reduction, or cause oxidation of ammonia present (forming more NOx). They require tuning to perform properly, which can be time consuming and cost restrictive and have a period during their start-up cycles where exhaust temperatures are too cool for NOx reduction to occur. This can lead to unchecked emissions and fines from government offices. When speaking specifically about coalfired power plants, SCR systems have
49
operational difficulty with binding of the catalyst by fly ash. Because of these issues, SCR catalysts have a limited operational lifetime of 16 to 40 thousand hours in coal-fired power plants, depending on the flue gas composition, and up to 80 thousand hours in cleaner gas-fired power plants. In selective non-catalytic reduction (SNCR) systems, a reagent is injected into the furnace to react with the heated flue gas and convert the present NOx into nitrogen and water, which can then be captured and stored. Though in theory SNCR systems can achieve roughly 90 percent removal rates, practical constraints like required minimum temperatures, time and mixing often lead to results ranging from 30 to 50 percent. Though SCR systems have been documented as more effective in NOx removal, SNCR systems are often favored due to their lowers cost since they do not use a catalyst. A typical SNCR system consists of reagent storage, multi-level reagent-injection and control instrumentation equipment. The SNCR reagent storage and handling systems are similar to those for SCR systems, but because of the higher stoichiometric ratios, both ammonia and urea SNCR processes require three or four times as much reagent as SCR systems to achieve competitive NOx reductions.
deadlines. Also, multi-pollutant technologies generally require a smaller footprint since their processes are encapsulated in one system. Given the advantages of multi-pollutant emissions control technologies, what are the barriers to larger scale deployment in the power sector? The primary barrier is that traditional emissions control technologies seem like a safe bet because they have been used by the industry for years. The owners of fossil-fired power plants know the capital investment, and operations and maintenance (O&M), costs of older technologies and operators can more easily anticipate problems that may arise.
particulate matter, into an oxidized, water soluble compound. The flue gas then passes through a series of high pressure fogging arrays that inject a water mist into the gas stream that creates a condensable acidic mist. The water mist cools the flue gas and the pollutants are condensed out from the flue stream once the temperature drops below the acid dew point. The waste stream is then treated, neutralized and disposed of safely. The remaining water can them be treated and recycled back into the process to conserve water. There are also several other technologies taking a multi-pollutant approach. Lextran Ltd reduces SOx, NOx and mercury. Like SCR systems, Lextrans ab-
Advanced Emissions Control Technoloy

FGD NOx SOx Mercury Particulate matter CO2 0 50 98% 0 0 N/A SCR 70 - 95% 0 0 0 N/A SNCR 30 50 % 0 0 0 N/A Multi-pollutant emissions control 85-98% 98-99% 95-98% 50-99% 30-75%
With multi-pollutant emissions control technologies, a single system is able to remove multiple pollutants from flue gas before they are released into the atmosphere. Currently, the emissions targeted include NOx, SOx, mercury and other heavy metals, halogens and particulate matter. However, the commercial readiness of multi-pollutant emissions control systems has been overlooked. Eco Power Solutions operates two of its systems one on gas-fired boiler and the other for coal-fired at their technology center in Louisville, Kentucky. Visiting engineers, investors and public officials can see, in real time, the performance of the systems in real world tests. As demonstrated during at technical tour at CoalGen 2012, the technology scrubbed the flue gas from the coal-fired boiler and removed 98.6 percent on NOx, 99.9 percent of SOx and captured 75.5 percent of CO2. Its system injects ozone and hydrogen peroxide into the flue gas stream to convert the criteria pollutants, which include NOx, SOx, mercury, acid gases and sorbs pollutants through a catalyst, in this case an organic substance in an emulsion form, in a wet scrubber environment process. The Lextran catalyst contains an active sulfur-oxygen functional group, having properties that enhance the oxidation reactions of SOx, and NOx into SO4 and NO3 anions. After initial oxidation the catalyst is released and recycled back into the process, leaving the pollutants in a chemical form amenable enough to become commercially beneficial by-products. They first must be neutralized by ammonia, KOH, or other basic reagents to control the type of by-products, which could include ammonium nitrate, ammonium sulfate, potassium sulfate and potassium nitrate. Hamon Research Cottrells ReACT system captures NOx, SOx and mercury
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ADVANCED EMISSIONS CONTROL TECHNOLOGY

With multi-pollutant emissions control technologies, a single system is able to remove multiple pollutants from flue gas before they are released into the atmosphere. Currently, the emissions targeted include NOx, SOx, mercury and other heavy metals, halogens and particulate matter. A considerable advantage of a multi-pollutant strategy is lower capital investment when compared with investing in several different technologies to address each pollutant. Likewise, the installation of a single unit is faster and requires less downtime. This is especially relevant due quickly approaching
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while reducing particulates. With this system, a moving bed absorber provides contact between flue gas and activated coke pellets, where SO2, SO3, NOx and mercury are absorbed onto the carbon surfaces. Ammonia is then injected upstream in order to promote the SO2 and NOx reactions as the moving bed acts as a particulate collection step. The impingement of the flue gas on the activated coke pellets provides polishing control of particulate. Cleaned flue gas moves to the smoke stack for discharge with little or no plume compared to SDA, CDS, or WFGD processes. Activated coke from the absorber is then processed in a regenerator vessel that completes the reduction of NOx to N2, and drives off SOx in a concentrated sulfur rich gas stream. Absorbed mercury is retained in the activated coke in a region of the regenerator where temperature conditions allow the mercury to accumulate.
Regenerated activated coke is screened to remove fines and returned to the absorber while the sulfur rich gas is processed using conventional technology to produce salable sulfuric acid. This process is best suited for utilities burning low sulfur coals, such as PRB coals, and for sites where water use, water treatment or discharge are issues.
TWO OPTIONS FOR THE INDUSTRY MOVING FORWARD

Power generators should understand that NOx and SOx are parts of a holistic emissions control strategy. MATS and MACT are only hints of what is to come. Most industry experts are expecting some form of carbon regulation and even stronger restrictions on the emission of heavy metals, acid gases and particulate matter. The industry faces two options:
continued reliance on the technologies that are meeting the needs of yesterdays regulations or investing in advanced emissions control technologies that meet the needs of today and tomorrow. Eco Power Solutions, Lextran Ltd and Hamon Research Cottrells technologies have already been short-listed by the EPA as systems that offer(s) the potential of reduced compliance costs and improved overall environmental performance. These technologies represent the forefront of innovation in the fossilpower generation industry and provide a cost-effective option to continue operating aging plants that still have significant service time available. Likewise, it is an option for co-ops and municipal utilities that lack the resources to invest in a series of traditional technologies yet do not have the option of shutting down their power generation facilities if they cannot comply.
NOx & CO Compliance Fuel Conversion

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With GEs Steam Cycle solution, users can significantly cut solution implementation time and avoid development delaysincreasing uptime and profitability. Photo courtesy of General Electric.
Pre-engineered Strategies Maximize Knowledge Base to Ensure Efficiency & Reduce Downtime
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BY ALAN HINCHMAN, GE GLOBAL MARKETING DIRECTOR-INFRASTRUCTURE & HEAD OF ENERGY, OIL & GAS, WATER AND COMMERCIAL BUILDINGS OFFERINGS
oday in the power industry, there are many companies that are dealing with an increasing number of plant engineers that are approaching retirement. The loss of that institutional knowledge is a challenge since boiler controls require experience to install, replace and operate. Years of experience are often needed to understand the art associated with controls at a
specific plant using specific auxiliary systems. Retaining the institutional knowledge of retiring engineers eventually nets out in the cost of time searching for the right candidates, training time and on-the-job experience can take years and thousands of dollars. The classic alternative is to use consultants to fill that void. However, there can also be a significant amount of time associated with training the
consultant and getting the solution implemented and tested as well as the additional use of consultants required whenever there needs to be a change in the system. Neither training new engineers nor utilizing consultants seems appropriate in todays world of increasing efficiency. The potential loss of institutional knowledge can be overcome in part by the use of pre-engineered control strategies. The intent is to allow power
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plants to obtain sophisticated control strategies without having to reinvent the wheel when it comes to controlling all of the elements required to deliver consistent steam to the turbine. Leveraging proven strategies ensures not only that the boiler will operate efficiently, but that it will also operate safely. Pre-engineered strategies can cut the implementation time of a new Distributed Control System (DCS), thereby allowing installation during a short maintenance outage. This allows the time savings to be realized months before a traditional DCS could be installed. This strategy also allows current operators to increase the operating efficiency of the plant while optimizing the labor resources required to perform specific tasks such as startup of heat recovery steam generators. Users
can implement sophisticated strategies used at larger power plants in midsized and smaller plants with more confidence and more quickly than installing a traditional DCS with custom or less sophisticated strategies. Additionally, the ease of installation is also accompanied by ease in changing the parameters to allow the knowledge of existing employees to be captured in the control system.
ADVANTAGES OF USING ADVANCED CONTROLS

Significant improvements can be made to boiler operations through advanced controls to help the plant to operate closer to the maximum nameplate ratings. Specifically, the benefits to be gained are focused on delivering consistent steam to the turbine. However, these improvements
in operations also focus on improving safety, decreasing emissions and decreasing consumption of excess fuel and water. Other benefits of advanced controls include reduction in capital costs for inconsistent Btu values in fuels. Sensors for determining the Btu content of the fuel (such as municipal solid waste) are expensive, and the benefits provided rarely cover the expense. Compensation from the software can provide a significant advantage to operations and limit the capital outlay. A DCS with sophisticated control strategies can increase the performance of mid- and small-size plants because they make sophisticated strategies, usually only found at large plants, available to all plants. The result is a plant that has higher efficiency and safety while providing consistent
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Viega ProPress for stainless is just quality at its best.

Sabina Pryce-Jones, JEA Northside Generating Station, Jacksonville, Florida
Meeting the strictest standards in North America, Viega ProPress makes secure connections in less than seven seconds. Versatile and reliable, Viega ProPress is available from " to 4" in copper or 304 and 316 stainless steel.
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As part of a capital improvement project, JEA Northside Generating Station (NGS), located in Jacksonville, FL, separated its originally unied water system and installed an independent potable water system.
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The system makes it really easy to work with because of the consistency of the connections. Its a consistent, repeatable product.
We thought it would be prudent to separate the systems and install a potable system that would supply nothing but our potable applications which included our drinking supply, hand washing, eye washing stations and safety showers, explained Sabina Pryce-Jones, Generation Operations and Maintenance Specialist at JEA. When this project was originally engineered, the specifcations required hundreds of welds with 304 stainless steel 4" pipe, said Ron Beverly, CFB Operations Specialist at JEA. When we started looking at alternatives, we found that Viega ProPress for stainless was available for 4" pipe and came in the 316, NSF-61 certifed stainless steel. Viega ProPress uses press fttings to make water-tight and air-tight connections. The system is comprised of stainless steel pipe, valves and fttings in sizes up to 4". It takes less than seven seconds to make a pressed connection, compared to more than an hour for some threaded and welded connections. The new potable water system included more than 6,000 feet of Viega ProPress stainless steel pipe and over 500 fttings. The system required connections to nine new pressure-reducing stations and more than 50 tie-ins.
The system makes it really easy to work with because of the consistency of the connections. Its a consistent, repeatable product, said Beverly. After the pipe brackets were put in place, installing and joining the pipe was very quick with the Viega ProPress system. We pressure tested the systems main header and it had zero leaks, said Beverly. That convinced everyone how good the system is. The potable water installation would not have been possible to complete within the project budget or desired timeline using the traditional pipe joining methods originally specifed in the plans. Welds for this project were cost- and timeprohibitive, explained Pryce-Jones. Due in part to using Viega ProPress, we actually returned almost 20 percent of the $1.1 million project budget, which is rare for capital improvement projects. Viega ProPress is just quality at its best, concluded Pryce-Jones. For more information on Viega ProPress for stainless, visit www.ViegaProPress.us or call toll free: 800-976-9819.
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steam to the turbine. Additionally, utilizing an advanced DCS can reduce the time required to implement a new DCS. The reduction in implementation time can save on custom engineering hours and allow for faster achievement of the efficiencies of sophisticated control strategies. Power plants are often faced with problems that challenge their operational efficiencies. Listed below are
turbine or turbines. When a boiler that supplies steam into a common steam header for multiple boilers is taken out of service, the other boilers will have to compensate to ensure smooth and consistent steam to the turbine. The varying load swings on the boilers may lead to unbalanced conditions which could cause varying steam delivery or in the worst case scenario, water carryover to the turbine.
boilers provides consistent steam delivery from the boilers. Consistent steam decreases fatigue on turbines, thus decreasing maintenance costs on turbines. Additionally, balancing the boilers provides safe operations of the boilers by not having one boiler providing for the load variation and increasing the temperatures in the boiler beyond the desired set point.
Oxygen analyzer delays can cause effciency loss

ID Fan
ANALYZER DELAY COMPENSATION OF O2 TRIM

Problem: During load swings, the O2 set point is adjusted based on a load index. There is, however, a delay from the O2 analyzer. If this delay is not taken into account, the control will incorrectly adjust the O2 either higher or lower than optimal, leading to efficiency loss through excess hot air escaping up the stack or a high level of combustibles exiting the stack with the flue gas. Losses of 1 percent or more of efficiency can occur during transients or ramping. Solution: The control strategies should provide O2 trim control with a minimum O2 set point (which is operator adjustable). The control strategies should account for analyzer response delays and incorporate these delays to improve response and thus efficiency. Value: Fuel usage is optimized during load swings which saves on fuel costs and reduces unintended emissions such as CO.
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some of the common problems plants face, and how sophisticated control strategies can address these problems. Often these are not implemented due to either a lack of knowledge about a control strategy solution, or the perception that the engineered solution is beyond the financial scope of a project. But what if that solution was preengineered, and the knowledge of how to solve that problem was part of a productized solution?
PLANT MASTER AND FUEL MASTER

Problem: Plants with multiple boilers are faced with balancing their output such that the steam delivery matches the load demand from the
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Solution: Proper system design should accommodate both a plant and fuel master. The plant master functionality should allow for selecting which controller is the overall plant master to allow maintenance on one of the boilers or its controls. The fuel master controls the feeders or pulverizers. Input to the fuel master is from the plant master. The fuel master should provide a balancing and auto loop response correction to account for the number of burners in automatic mode versus manual mode or out-of-service for maintenance. Manual operation of a burner should not be required even during ramp-up or while using fuel with varying Btu content. Value: Correct balancing of the
STEAM FLOW COMBUSTION CONTROL IN STOKER BOILERS

Problem: Solid fuels fired on grates such as coal, biomass and municipal solid waste have varying Btu per measured weight, and constant heat cannot be assured as when using natural gas or oil. The available Btu must be inferred in order to control relative air flow to maintain suitable combustion. Unfortunately, O2 trim cannot
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be used exclusively to control combustion because of outside air impingement, uneven fuel bed and over-fire air stratification (O2 content should be more of an operator guide in this type of boiler). Solution: A steam flow/air flow
approach with the steam flow corrected for heat storage is utilized. This ensures that the combustion process is efficient and safe. The use of the adjusted steam flow/air flow system over a basic parallel system can increase efficiency by five percent or more. A minimum
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air set point and smother protection override also provides increased safety and boiler availability. Value: Both safety and maintenance concerns are alleviated by properly controlling the combustion cycle. By allowing a minimum air set point, the combustibles in the stack are limited below hazardous levels. Maintenance concerns are minimized by providing more consistent steam flow, thereby decreasing fatigue on the turbine.
COMPENSATION FOR MULTIPLE FANS, FEEDERS AND STOKER RESPONSE

Problem: When multiple devices like feeders, FD and ID fans, etc., are controlled from a single PID loop, it is desirable to compensate the loop for the number of devices in manual mode for activities such as manual loading in order to maximize loop response. Upsets due to poor response can lead to decreases in efficiency and mechanical stress. Solution: Control strategies should automatically adjust the control loop response based on the status of the individual driven devices. For example, where multiple feeders are driven from a single master fuel controller, the loop automatically compensates the fuel control loop as a feeder is put in or out of service and compensates for the weighted capacity of the specific feeder to minimize fuel feed upset. A bumpless slow automatic balance is provided to restore the device to the demand signal value when it is put back in service and set to automatic. Value: Minimizing upsets in the boiler loading process leads to more consistent steam delivery. Improving the PID loop response by understanding that devices come in and out of service will allow better system response from monitoring available devices only.
When OPPD was ready to optimize their plant to address dust mitigation, they turned to Martin. Martin conducted a safety and materials handling audit, which led to rebuilding coal transfer points to contain dust and reduce spillage and installing Martin Air Cleaners on load zones to further reduce the escape of fugitive materials.
Martin has been very responsive... throughout our on-going relationship, giving us competitive pricing, standing behind their product and ensuring that they operate reliably, said Kirk Estee, P.E. Material Handling Supervisor at OPPD. OPPD was recently named Plant of the Year by the PRB Coal Users Group.
call 1 800 544 2947 | email info@martin-eng.com visit martin-eng.com

Registered trademark of Martin Engineering Company in the US and other select locations. 2013 Martin Engineering Company. Additional information can be obtained at www.martin-eng.com/trademarks.
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Entergy Blends A Dedication To Energy With A Dedication To Customers

BY JUSTIN MARTINO, ASSOCIATE EDITOR
ntergy may have started with burning sawdust to generate power, but since then the company has grown to build a diverse foundation of power-generating projects. Entergy began in 1913 when Harvey Couch, president of Arkansas Power Co., made a handshake agreement with H.H. Foster, president of the Arkansas Land and Lumber Company, to generate power from sawdust from Fosters lumber company. Arkansas Power Co., which provided power for two Arkansas towns, started with two 550 kW generators and 22 miles of transmission lines. One hundred years later, the company has 30,000 MW of generating capacity, revenues of more than $10 billion and is one of the leading nuclear generators in the U.S.
BUILDING A DIVERSE POWER GENERATION PORTFOLIO

Entergy, which is based out of New Orleans, provides power for around 2.8 million customers in four states and operates more than 40 power plants in the U.S. The companys power generators run off of a variety of fuel and include coalfired, natural gas-fired, hydroelectric and nuclear generators. Having that level of fuel diversity helps Entergy keep its prices as low as possible
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for its utility customers, said Jeff Richardson, Entergys Director of Major Projects Nuclear. When you have spikes in natural gas prices or coal or oil or uranium prices, we have enough fuel diversity to shield our customers from those kinds of volatile actions in the commodities markets, Richardson said. In addition, having a diverse fuel mix allows Entergy to help control its emissions. Entergys nuclear reactors can help offset emissions from other power generating sources, such as coal-fired power plants. Richardson noted that nuclear power is not only a cost-effective and less-volatile source of energy, but it also provides a near-zero emissions source of power generation. From that perspective, we think nuclear has very strategic advantages in the long term in a world thats more and more concerned with the multi-pollutant requirements and concerns about climate change and CO2 and those kinds of things, he said. On the fossil fuel side of power generation for Entergy, Entergy Vice President Fossil Generation Etienne Senac said the company is currently working more with natural gas than coal, although the company still has three coal-fired power plants with five total units. Senac said that while coal is still being used globally, uncertainty about regulations in the U.S.
as well as costs have pushed the U.S. toward using more natural-gas fired power plants. Were kind of all being funneled in the gas technologies at the present time because people just dont see where the future of coal is going to be in the United States, he said.
NINEMILE STATION
Entergys most current large project follows the trend of using natural gas rather than coal for power generation. The company is building a combined cycle gas turbine unit, Ninemile 6, located at its current Ninemile Point plant in Westwego, La. that will provide 550 MW of power capacity. The unit, which will cost $721 million to construct, will be one of the most efficient gas-fired units in Entergys fleet as well as in the state, according to the company. It will replace Ninemile units 1 and 2, which first came online in the early 1950s and have been deactivated. The company said the unit will have significantly lower emissions than the units that were deactivated and will be one of the cleanest gas-fired generating units in the U.S. The unit will use GE 7FA.04 combustion turbine generators and a Toshiba TCDF 33.5 steam turbine generator. The heat recovery steam generator is a model manufactured by Vogt. Entergy is using subsidiaries of CB&I as
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Entergys Hot Spring power plant is one of its natural-gas fired power generation plants.
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The Hot Spring plant is located in Arkansas, which is one of four states that Entergy serves.
engineering, procurement and construction contractors. Were pretty happy that were back to building some generation, Senac said. Building Ninemile 6 is part of Entergys plan to continue to change its sources of power generation in order to continue to provide efficient, reliable and lower-cost electricity to its customers. Besides building the unit, the company is also planning to acquire combined cycle gas turbine units for sale when the purchase is economical and would meet reliability needs. The company also intends to enter into long-term agreements with suppliers of efficient, lower-cost power. Entergy has also recently completed several major projects for its nuclear power generation, including a steam generator replacement at its Waterford 3 unit in Killona, La., and a power uprate at its Grand Gulf Nuclear Station in Port Gibson, Miss. Although no projects on the scale of the Grand Gulf uprate or Waterfords steam generator replacement are planned at any of its stations currently, Richardson said Entergy spends millions of dollars each year at each of its nuclear sites for capital upgrades. Those upgrades may involve adding automation, upgrading computer and mechanical systems or adding facilities for employees at the stations. Entergy works with multiple companies for its capital upgrades at nuclear sites, including Westinghouse Electric; GE Hitachi, a consortium between the two companies that focuses on nuclear operations; Areva; and Siemens. Richardson also said the company continues to look for ways to expand Entergys business in areas where it makes
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sense to the company, including providing license renewal services to other utilities and contracting for operations at nuclear power plants owned by other companies.
DEALING WITH UNCERTAINTY IN EXPANSION

As Entergy continues with its longterm plans and goals, looking at regulation and potential changes in the market will be important to making decisions that will help the company continue its success, Senac said. Although natural gas may appear to be the best fuel to be using right now, changes in the market could raise prices and make another fuel more desirable. You always have to keep your options open and think about diversification, where it makes sense, because certainly, as weve seen historically, youve got potential for a lot of volatility in the price of fuels, he said. Senac noted that as more coal units are being shut down, and some companies consider closing down nuclear units, more power plants in the U.S. will likely switch to using natural gas for power
generation, increasing the demand. In addition, the U.S. Environmental Protection Agency is researching potential environmental damage caused by hydraulic fracturing, a method used to obtain natural gas, which could lead to more regulations in the future. The whole natural gas industry could be impacted by that, and you could see a price rise in natural gas due to demand and environmental regulation, he said. Environmental regulation plays a large role in the future of the companys coalfired power generation as well. Federal regulations regarding emissions are forcing many U.S. coal-fired power plants to either shut down or make major investments in emissions control technology. Senac said there are no regulatory mandates that would require any of the companys five coal-fired units to install scrubbers at this time, but the company continues to monitor all regulations that come out. Based on final rules being made by the EPA, the company will make decisions on capital improvements to its current energy fleet. Four of the companys coal-fired units are in Arkansas, which is currently putting together a state implementation plan
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for EPA regulations. A lot depends on how that turns out, Senac said. If the company will be required to install scrubbers on its coal-fired units, Senac said it will look at the economics of the regulations, along with the cost of fuel, and make a decision on how to proceed based on those factors. We think probably in the next two or three years well get a little bit of clarity and more certainty on some of the regulations, he said. I think its difficult for the industry because there is a lot of uncertainty sur-
worked on ways to reduce emissions to help reduce the impact of global climate change. The company was the first U.S. utility to voluntarily commit to stabilize its greenhouse gas emissions, and J. Wayne Leonard, who retired as chairman and chief executive officer of Entergy on Jan. 31, has advocated for a per-ton fee on carbon emissions. You start to find yourself posing the question of After I die, what?, and then it really starts to dawn on you that the real question is, Before I die, what? Leonard said in a speech to members of the National Wildlife Federation while accept-
Entergys current project, a new combined cycle natural gas-fired unit, will be located at its current Ninemile Point plant.
choose to invest in it as well. He warned, however, that it is also important to not get too far ahead of what is required because of potential cost recovery issues with regulatory commissions but added the company is taking steps to reduce emissions on current units as well as retiring older, less efficient units to cut down on emissions. Entergys nuclear fleet also helps in reducing emissions created from power generation. Entergy was named in the 2012/2013 Dow Jones Sustainability North America and World Indices and the 2012 Carbon Disclosure Leadership Index. It was one of only two U.S. companies in the electric utility industry selected to the Dow Jones Sustainability World Index. Being named to the indices marked the 11th consecutive year the Dow Jones Sustainability Index has included Entergy on either the world or North America index. In addition, Entergy has been named to the Carbon Disclosure Leadership Index eight of the past nine years. I think as a company we have done a very good job trying to reduce our total emissions, Senac said.
GIVING
rounding the regulations and the standards. A lot of these things we see, we anticipate that regulations are going to come out and next thing you know, things get held up in the court system, they get overturned and vacated. When youre looking at billions of dollars worth of capital investment and infrastructure, the uncertainty really is a big, big detriment to that. You just dont have many people today that want to step out and build sizable coal units in the United States because theres just so much uncertainty. ing an award for Entergys environmental programs last November. I can think of no time in history when the planet is in as much peril as it is today, he said. We were not supposed to be facing the possibility of mass extinctions in anybodys lifetime ... but here we are. Senac said one of Leonards issues, and an issue likely to continue to be looked at by current chairman and CEO Leo Denault, is how to encourage investments in technology that can reduce emissions and be used globally. Senac said it will be key for manufacturers to produce viable technology that can be used on a commercial scale and also makes enough economic sense that other countries will Entergys dedication to helping improve quality of life isnt limited to just its emissions, however. The company works to help its customers and is active in giving to charities, including endowing a $5 million charitable fund in Leonards name when he retired from the company. The charitable fund was endowed through shareholder-funded donations to the Entergy Charitable Foundation. During Leonards tenure as CEO, which began in 1999, Entergy has donated more than $50 million to charitable initiatives and advocacy efforts that successfully helped move low-income residents toward self-sufficiency, including $16.5 million in grants in 2011 to improve the quality of life in the areas where it operates. Among them were campaigns to improve early childhood
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A COMMITMENT TO THE ENVIRONMENT

Despite the uncertainty around regulations for energy companies, Entergy has
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education programs and financial support of a matched-savings program that has helped 19,000 people and created an economic impact of $69 million over the last 10 years. I think that we are a very caring company that is truly concerned about our customer base, Senac said. He added the companys service territory includes areas with some of the highest poverty rates in the U.S., and the company is very passionate about doing everything it can to provide reliable service and the lowest possible rates for its customers. Having low rates not only helps its residential customers, but it also helps keep costs down for the companys industrial base, which helps spur economic growth in the area. Senac said it is also important to provide reliable service for Entergys customers.
Ninemile Unit 6 will cost around $721 mn to build and will provide 550 MW of energy.
I think we have excellent reliability performance, especially in the area we serve where we have some of the greatest fluctuations of power on a daily basis, he said, noting that the southern U.S. can have large energy peaks in the summer because of the air conditioning loads and
other similar factors. Another part of providing the best possible services to Entergys customers is an ability to respond quickly to major storm events, which can include everything from hurricanes to ice storms in Entergys service area. Senac said the company has
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a long history of handling storms and is recognized across the industry for its ability to do so. It really is what I would consider one of our core competencies, he said. Where we live, were kind of under the constant threat all across the summer of having storms.
ago, growth and change is not a new concept. Senac said there has been rapid technological change in the past 25 years, and he expects Entergy to take advantage of that change to better serve its customers. If you just think about
advancements in technology, communications, the medical arena, just the growth and demand for energy across the globe I think its going to be continuous, he said. I think youll see phenomenal change in the next quarter of a century.
STILL GROWING
As Entergy continues to work best to serve its customers, the company will continue to go through improvements and upgrades. I do believe that our entire industry is at a critical juncture, Senac said, adding that a lot of utilities are hitting the same century mark as Entergy and that there is a lot of infrastructure in the utility industry that requires upgrading. Entergy has worked to make upgrades in its infrastructure and changes to benefit its customers, and recently has proposed some changes with its transmission business. It has received all necessary approvals from regulators in Arkansas, Louisiana, New Orleans, Mississippi and Texas to join the Midcontinent Independent Transmission System Operator, which is planned for December 2013. Customer savings are projected to reach approximately $1.4 billion in the first decade of MISO membership, according to Entergy. In addition, Entergy and ITC Holdings Corp. filed a joint application with the Federal Energy Regulatory Commission for approval to spin off and merge Entergys transmission assets into a subsidiary of ITC. The move, announced in December 2011, would allow for greater capacity for investment, singular focus and excellence in operations, according to Theo Bunting, Entergys group president of utility operations. The companies hope to receive all regulatory approvals and complete the transaction in 2013. For a company that began with a handshake agreement and two sawdustoperated power generators 100 years
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Single-phase FAC. Note the orange peel texture. Photo courtesy of Dave Johnson, ChemTreat.
Many 100s of plant assessments worldwide, and Numerous fatalities and serious failures, and Much application and development This article focuses upon FAC and methods to prevent it, and will hopefully serve as a warning document for plant management at the many hundreds of facilities that continue to be constructed and brought on-line not only in the U.S. but worldwide. When I began my utility career in 1981, conventional wisdom said that any dissolved oxygen which entered the condensate/feedwater system of utility boilers was harmful. At that time, more than 50 percent of the power produced in the U.S. came from coal. Coal-fired units typically have complex condensate/feedwater networks with numerous feedwater heaters. The prevalent thinking was that any trace of dissolved oxygen (D.O.) would cause corrosion, and indeed oxygen corrosion can be very problematic in uncontrolled situations. Therefore, virtually all feedwater systems for high-pressure steam generators were equipped with a deaerator for dissolved gas removal. A properly operating deaerator can lower D.O. concentrations to 7 parts-per-billion (ppb). However, any residual D.O. concentration was still considered harmful, so chemical deaeration was a standard process at most plants. The workhorse for many years was hydrazine (N2H4), a reducing agent which reacts with oxygen as follows: N2H4 + O2 2H2O + N2 Eq. 1
Plant Management:
Dont Lose Focus on FAC Issues
A
68
BY BRAD BUECKER, CONTRIBUTING EDITOR
main topic at the spring 2013 meeting of the ASME Research Committee on Power Plant & Environmental Chemistry was once again flow-accelerated corrosion (FAC) and its prevention. The issue has not lost any importance since four workers were killed by an FAC-induced failure in 1986, [1] with a number of fatalities since. In fact, FAC is the top corrosion mechanism in heat recovery steam generators (HRSG), so the issue has, if anything, become more important. However, as was pointed out by several of the meeting attendees (and most notably Dr. Barry Dooley of Structural Integrity Associates and formerly of EPRI),
concern over FAC seems to be fading away in the minds of plant management at many facilities. A contributing factor undoubtedly is the many retirements in the power industry, where new personnel simply do not understand the importance of FAC control. Yet, FAC continues to generate international conferences, the most recent of which was held in March in Washington, D.C. In a presentation to the PPEC meeting attendees, Kevin Shields, one of Dr. Dooleys colleagues, provided the following bullet items in an introductory slide. [2] FAC occurs in >70% of fossil plants, and represents >40% of all tube failures in HRSGs despite R&D since the 1960s, and
Also, a primary, and arguably the primary, benefit of hydrazine is that it will passivate oxidized areas of piping and tube materials as follows:
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Photo of tube-wall thinning caused by single-phase FAC. Photo courtesy of Dave Johnson, ChemTreat.
N2H4 + 6Fe2O3 4Fe3O4 + N2 + 2H2O Eq. 2 N2H4 + 4CuO 2Cu2O + N2 + 2H2O Eq. 3 Fe3O4, magnetite, is the protective layer that forms on carbon steel when it is placed into service. Cu2O forms on copper alloys, although we will not discuss this chemistry in great depth, as the use of copper alloys in condensate/feedwater systems has greatly diminished in large part due to the potential for copper carryover to steam in high-pressure utility boilers. Hydrazine residuals were typically maintained at relatively low levels of perhaps 20 to 100 parts-per-billion (ppb). Oxygen scavenger treatment was coupled with feed of ammonia or an amine to maintain feedwater pH within a mildly alkaline range, now 9.1 to 9.3 for mixedmetallurgy feedwater systems and a bit higher for all-ferrous systems. NH3 + H2O NH4+ + OH
70
Eq. 4
This program became Carbon Steel Matrix Dissolutionas a known as all-volatile treatFunction of pH and Temperature ment reducing [AVT(R)]. Due to the suspected carTemperature (F) cinogenic nature of hydra0 122 212 302 392 482 572 662 zine, alternative chemicals 100 such as carbohydrazide, NH3 pH methyl ethyl ketoxime, 0.1 ppm 8.75 and others gained popu0.2 ppm 8.90 larity. Regardless, all still 0.3 ppm 9.05 80 had the same purpose, to 0.5 ppm 9.20 1.0 ppm 9.40 establish a reducing envi2.0 ppm 9.60 ronment in the feedwater circuit, thus inhibiting oxi60 dation of metal. The technique became a standard in the industry. 40 This changed in 1986. On December 9 of that year, an elbow in the condensate system ruptured 20 at the Surry Nuclear Power Station [near Rushmere, Va.] The failure caused four fatalities and tens of mil0 lions of dollars in repair 0 50 100 150 200 250 300 350 costs and lost revenues. [1] Temperature (C) Researchers learned from this accident and others that the reducing environment produced dissolution is greatly influenced by not by oxygen scavenger feed results in single- only reducing conditions but also by sophase flow-accelerated corrosion (FAC). lution pH and temperature. The attack occurs at flow disturbances As Figure 1 illustrates, corrosion reachsuch as elbows in feedwater piping and es a maximum at 300 F. Thus, feedwater economizers, feedwater heater drains, systems and HRSG low-pressure evaporalocations downstream of valves and re- tors are particularly susceptible locations. ducing fittings, attemperator piping, and, Also note the influence of pH, as reflectmost notably for the combined-cycle in- ed by ammonia concentration, on the dustry, in low-pressure evaporators. The corrosion characteristics. As we shall see, effect of single-phase FAC is outlined in this factor is quite important with regard the next illustration. to control of FAC. Metal loss occurs gradually until the The quest to maintain a non-detectable remaining material at the affected loca- oxygen residual in feedwater systems led tion can no longer withstand the process to FAC at many coal-fired power plants. I pressure, whereupon catastrophic failure observed this first hand at one of two utiloccurs. The thinning is due to the com- ities in which I was employed in the past. bination of a reducing environment and At this plant, a feedwater heater drain line localized fluid flow disturbances, which failed due to FAC, shutting down an 800 cause dissolution of ferrous ions (Fe+2) MW supercritical unit. Infinitely more from the metal and metal oxide matrix. serious was FAC-induced failure of an atResults from EPRI showed that iron temperator line in 2007 at another of the ppb Fe
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utilitys stations, which killed two workers and seriously injured a third. In large measure, coal plant personnel have recognized the problem of singlephase FAC, and have adopted alternative feedwater treatment methods to mitigate the issue. However, I regularly review combined-cycle proposals in which the developer specifies an oxygen scavenger feed system for
HRSG chemistry control. It is obvious that this mindset clearly has not been expunged at many locations.
SOLUTIONS TO SINGLEPHASE FAC AND CHANGING THE REDUCING-AGENT MINDSET

HRSGs by their very nature typically have many waterwall tubes with
short-radius elbows. Thus, the HRSG contains numerous spots susceptible to single-phase FAC. A primary method to mitigate this attack is selection of proper feedwater treatment, which we will now examine. More than 40 years ago, researchers in Germany and then Russia began using a program known as oxygenated treatment (OT) to minimize carbon steel corrosion and iron dissolution in supercritical steam generators. The key component of the program was, and still is, deliberate injection of pure oxygen into the condensate/feedwater network to establish oxygen residuals of up to 300 ppb. What chemists discovered is that in very pure feedwater (cation conductivity, 0.15 S/ cm), the magnetite becomes overlayed with a tenacious and very insoluble film of ferric oxide hydrate (FeOOH). Results quickly showed that OT can lower feedwater iron concentrations to 1 ppb or less, and greatly minimize single-phase FAC. Now, OT is the preferred feedwater treatment for once-through utility steam generators around the world. Common in the United States is an oxygen residual range of 30 to 150 ppb, with a recommended pH range of 8.0 to 8.5. OT has been applied to a few drum units, where EPRI guidelines call for a feedwater pH range of 9.0 to 9.4 with a dissolved oxygen concentration of 30 to 50 ppb. Although OT has been successfully applied to drum boilers, another program has evolved that is very popular for condensate/feedwater in these steam generators. To this point in time with AVT(O), oxygen has not been deliberately injected into the condensate, but rather the amount that enters from condenser air in-leakage (per normal conditions, where we will examine normal shortly) is allowed to remain without any oxygen scavenger/metal passivator treatment. It should be noted at this point that OT or AVT(O) are not permissible for feedwater systems containing copper alloys, as the oxygen would simply be too corrosive to the metal. The following
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72
text therefore focuses upon AVT(O) for all-ferrous systems. When researchers developed AVT(O), they took into account the pH effect on carbon steel dissolution, as previously illustrated in Figure 3. AVT(O) guidelines evolved to the following parameters. Recommended pH range, 9.2-9.6 Feedwater D.O. concentration, 1-10 ppb As with OT, the condensate in an AVT(O) programs must be quite pure to allow oxygen to generate the FeOOH protective layer rather than cause pitting. However, the cation conductivity upper limit with AVT(O) is a bit more relaxed at 0.2 S/cm. AVT(O) chemistry is evolving. Chemists have discovered that even 10 ppb D.O. in the feedwater may not be sufficient to generate a complete FeOOH passivation layer. It is possible that deliberate injection of oxygen, similar to OT programs, may in the future be recommended where needed. The amount of air in-leakage that establishes the normal condition of 10 ppb or less dissolved oxygen in the condensate is not a hard and fast value. The old rule of thumb for proper condenser conditions is a limit of 1 scfm (standard cubic feet per minute) of air in-leakage per 100 MW of capacity. However, I have worked with units in which the air inleakage ratio was significantly higher, but where the condenser vacuum pumps had sufficient capacity to remove the gases. Quite often, a failure at the condenser shell or within auxiliary equipment may cause a sudden spike in dissolved oxygen concentration. As contrasted to pure oxygen feed such as with OT, air in-leakage also allows carbon dioxide to be drawn into the condensate, which raises the conductivity. In such cases, plant personnel need to search for the leak or leaks and repair them promptly. Much more problematic is a condenser tube leak, which not only raises the condensate dissolved solids concentration, but introduces
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impurities to the steam generator. These effects can be quite dramatic.
ADDITIONAL CHEMICAL AND MATERIAL SELECTION TECHNIQUES TO MINIMIZE FAC

Elevated pH also has a beneficial effect in mitigating FAC. Thus, the guidelines
for feedwater pH now recommend a range of 9.2 to 9.6. With EPRIs phosphate continuum program or with caustic treatment alone, the drum pH can be controlled within a range of 9 to 10 quite readily. However, a complication sometimes arises due to HRSG design. Most HRSGs are of the multi-pressure, drum, vertical tube style. In some cases,
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Two-phase FAC in a deaerator. Photo courtesy of Tom Gilchrist, Tri-State G&T (ret.)
the feedwater circuit is designed such that feedwater separately enters each pressure circuit separately. In many others, however, the entire feedwater stream is routed to the low-pressure (LP) evaporator for heating before being distributed to the intermediate-pressure (IP) and high-pressure (HP) steam generators. For this configuration, phosphate or caustic feed to the LP circuit is not permissible due to the downstream effects on attemperator chemistry, and IP and HP economizers. In these situations, LP pH control is dependent upon the ammonia injected into the feedwater. If the condenser is tubed with ferrous materials, the pH may be taken higher than the 9.2 to 9.6 range listed above without ill effects. However, copper-alloy tubes would suffer corrosion at higher ammonia concentrations. For new HRSGs, single-phase FAC control can also be addressed by materials selection. The addition of a small amount of chromium in the material at FAC-susceptible locations virtually eliminates the corrosion. A primary example is LP waterwall elbows. Fabrication of the elbows from 1 or 2 chrome alloy can provide great benefit. While this alloy addition adds some cost to the project, the materials are quite resistant to FAC.
TWO-PHASE FAC
Many steam generators, regardless of type, are susceptible to two-phase FAC. As the name implies, this corrosion mechanism occurs where water flashes to steam, resulting in a mixedphase fluid. For conventional units, feedwater heater shells and heater drains are common locations for two-phase FAC, but this equipment is not common for HRSGs. However, deaerators also experience
74
two-phase fluid flow. As fluid flashes upon entering a deaerator, oxygen departs with the steam. Thus, the water that impinges upon metal surfaces does not maintain an oxidizing environment. Also, the pH of entrained water droplets within the steam is usually lower than the bulk water pH. The combination of these factors often initiates FAC. As has been noted, elevated pH will help to mitigate FAC, but the HRSG configuration dictates how the maximum treatment allowed. If the LP system is utilized for heating of feedwater to the IP and HP circuits, solid alkali treatment (trisodium phosphate or caustic) of the LP circuit is not permissible. Control of pH can only be accomplished by ammonia, but it should be noted that ammonia hydrolysis, as previously outlined in Equation 4, decreases with increasing temperature. As with single-phase FAC, a method to combat two-phase FAC is fabrication of susceptible locations with chromium-containing steel. Again, this adds cost to the project.
CONCLUSION
FAC is an issue to be taken very seriously. I continue to see a large number of power plant proposals that still call for an oxygen scavenger feed system, and this is quite frustrating. In addition to the references I have included in this article, I also encourage readers to access the web site of the International Association for the Properties of Water and Steam (www. IAPWS.org). This group, in which Dr. Dooley is one of the directors, offers free downloadable and cutting-edge technical information regarding power plant water/steam chemistry. References Guidelines for Controlling Flow-Accelerated Corrosion in Fossil and Combined Cycle Plants, EPRI, Palo Alto, CA: 2005. 1008082. K. Shields, [A report on the] International Conference on Flow-accelerated Corrosion in Fossil, Combined-Cycle/HRSG and Renewable Energy Plants at the 2013 spring meeting of the ASME Research Committee on Power Plant & Environmental Chemistry, April 15-17, Houston, Texas.
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equipment from sliding or moving. Designed for through hole installation, the rubber pocket bumpers offer a 60-70 durometer range and are available in 29 sizes from .500 (12.7 mm) to 2.500 (63.5mm) to accommodate various mounting holes and panel thicknesses, and to provide vibration dampening. They are constructed out of Styrene Butadiene and have an operating temperature range of -40F (-40C) to 221F (105C). Heyco Products Inc. Info http://powereng.hotims.com RS#: 403 www.power-eng.com
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ierra Monitor has introduced the new IT Series network-enabled gas detectors, feaput, RS-485 Modbus output, HART, integral relays, SentryBus output and extensive self-diagnostics for reliable, accurate monitoring. The IT Series meets the user
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POWER GENERATION WEEK

4 Events. 5 Days. 1 Roof.
NOVEMBER 1214, 2013 | ORANGE COUNTY CONVENTION CENTER | ORLANDO, FL, USA
Covering every aspect of the power generation industry, POWER-GEN International, NUCLEAR POWER International, Renewable Energy World Conference & Expo North America and POWER-GEN Financial Forum converge in 2013 to form POWER GENERATION WEEK. Beneft from fve days packed with pre-conference workshops, technical tours, over 70 conference sessions, panel discussions, three exhibition days and multiple networking events. Like never before, youll have access to nearly every facet of the market all under one roof.
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vertical transportation applications. Available in 3- and 6-pole variants, 730 Series female sockets utilize IDC to tap individual conductors at any place without Male employ CAGE stripping. plugs vibraCLAMP
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itron introduces the Quick Talk RQT, an industrial-grade radio transmitter with sentomatically alerts radio - equipped personnel plant change. The RQT radio can operate when conditions
sor inputs and voice recording storage that au-
incoln Electric says its Arc Products weld tracking and positioning systems are made to
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ti o n - re sis ta nt Spring Pressure Connection Technology to ensure reliability within elevator shafts. 730 Series is rated 300V/10A; female sockets accommodate fne-stranded conductors AWG 1816, male plugs accommodate solid, stranded and fne-stranded conductors AWG 2814. Created for switching functions, e.g., door switches or interlocks, 730 Series bright orange 3-pole Wire-Tap Branch Connector features an Isolation Blade that automatically cuts and isolates Live conductors in one step. WAGO Corporation
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Slide control systems for manual joint positioning and Cross Slide Assemblies to mount submerged arc or GMAW single or tandem welding arc equipment. All of the products are designed for wind tower section fabrication as well as tanks, pipe, pressure vessels, beams and stiffeners and rims/ wheels. Arc Products Info http://powereng.hotims.com RS#: 415
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AGO Corporations 730 Series Wire-Tap Branch Connectors expedite terminations
for facility managers and engineers overseeing
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GENERATING BUZZ
Helical Robotics
Wisconsin-based Helical Robotics offers fve different-sized
robots: the HR-MP5 (shown), the HR-MP20, the HR-MP100, the HR-JP10 Javelin and the HR-JP10M Javelin. The robots are remote controlled and can scale the wind tower while carrying cameras, tools and other equipment needed to inspect the towers, blades or other parts that may be dangerous or diffcult for workers to access. Deployment takes less than a minute and the robot can be used on a wide range of towers, the companys website says. Most of the robots are magnetic, which helps them to cling on to the side of a wind turbine.
www.power-eng.com
81
Progressive Changes
for the future
Be sure to mark your calendar to return to North Americas most inuential all-renewable event November 12-14 in the Orange County Convention Center Orlando, FL. Once again, well be co-locating with POWER-GEN International bringing renewable energy to the forefront of the mainstream energy industry.
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Nov. 12-14, 2013 Orange County Convention Center Orlando, FL
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Air Pollution Control
Automatic Filters
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Concrete Buildings
Demolition/Decommissioning
EPC Firm
Brandenburg
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Gear Lubricants
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Lubricant contamination caused by ferrous metals negatively impacts the operation of your critical rotating equipment. Philadelphia Gears COREFiltration System virtually eliminates ferrous metal particles, even as small as one micron, making this problem a thing of the past. For more information visit: www.philagear.com.
in Existing and Evolving Energy Needs
2013 Exxon Mobil Corporation. All trademarks used herein are trademarks or registered trademarks of Exxon Mobil Corporation or one of its subsidiaries.
Heat Recovery
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x x x Eliminate valve cavitation by placing one or more diffusers downstream of the valve. Noise and pipe vibration will also be eliminated or reduced. Valves first costs and maintenance burden will also be reduced.
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NOISE?
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(610) 631-3480 www.turbogen.net info@turbogen.net
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20,000 - 400,000 #/Hr. 50 - 25,000 KW 25 - 4000 HP
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444 Carpenter Avenue, Wheeling, IL 60090
Pugmill Systems, Inc.

P.O. Box 60 Columbia, TN 38402 USA Ph: 931-388-0626 Fax: 931-380-0319
FIND CONDENSER LEAKS FAST WITH FOAM METHOD LEAK DETECTION, TUBE PLUGS IN STOCK
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CONDENSER OR GENERATOR AIR COOLER TUBE PLUGS THE CONKLIN SHERMAN COMPANY, INC.
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Ph# 800-726-1026 Condenser & Heat Exchanger Tools www.johnrrobinsoninc.com

GEORGE H. BODMAN, INC.
Chemical cleaning advisory services for boilers and balance of plant systems
John R. Robinson Inc.
Just Plugging Along
George H. Bodman
Pres / Technical Advisor
P.O. Box 5758 Kingwood, TX 77325-5758 email: blrclgdr@aol.com
Office (281) 359-4006 1-800-286-6069 Fax (281) 359-4225
rental equipment
1-800-990-0374 www.rentalboilers.com
Rental Boilers Deaerator Systems Economizers Water Softener Systems 24-Hour Emergency Service
the steam & power special forces
*HW D %RLOHU 5HQWDO 4XRWH ZLWKLQ RQH KRXU DW ZZZZDUHLQFFRPHTXLSPHQW RU FDOO
INDEX
RS# COMPANY
14 Ail Sound Walls
alisoundwalls.com
PG#
26 65 9 14 38 3 C3 23
RS# COMPANY
21 3 7 9 Michigan Seamless Tube
www.mstube.com
PG#
37 7 15 19 59 53 17 80 43 79 C4 31 75 82 55 35 21 51 5 11 30
SALES OFFICE
1421 S. Sheridan Rd., Tulsa, OK 74112 Phone: 918-835-3161, Fax: 918-831-9834 e-mail: pe@pennwell.com Sr. Vice President North American Power Group Richard Baker Reprints Foster Printing Servive 4295 Ohio Street Michigan City, IN 46360 Phone: 866-879-9144 e-mail: pennwellreprint@fosterprinting.com National Brand Manager Rick Huntzicker Palladian Professional Park 3225 Shallowford Rd., Suite 800 Marietta, GA 30062 Phone: 770-578-2688, Fax: 770-578-2690 e-mail: rickh@pennwell.com AL, AR, DC, FL, GA, KS, KY, LA, MD, MO, MS, NC, SC, TN, TX, VA, WV Brand Sales Manager Dan Idoine 806 Park Village Drive Louisville, OH 44641 Phone: 330-875-6581, Fax: 330-875-4462 e-mail: dani@pennwell.com CT, DE, IL, IN, MA, ME, MI, NH, NJ, NY, OH, PA, RI, VT, Quebec, New Brunswick, Nova Scotia, Newfoundland, Ontario Brand Sales Manager Tina Shibley 1421 S. Sheridan Road Tulsa, OK 74112 Phone: 918-831-9552; Fax: 918-831-9834 e-mail: tinas@pennwell.com AK, AZ, CA, CO, HI, IA, ID, MN, MT, ND, NE, NM, NV, OK, OR, SD UT, WA, WI, WY, Alberta, British Columbia, Saskatchewan, Northwest Territory, Yukon Territory, Manitoba International Sales Mgr Anthony Orfeo The Water Tower Gunpowder Mills Powdermill Lane Waltham Abbey, Essex EN9 1BN United Kingdom Phone: +44 1992 656 609, Fax: +44 1992 656 700 e-mail: anthonyo@pennwell.com Africa, Asia, Central America, Europe, Middle East, South America European Sales Asif Yusuf The Water Tower Gunpowder Mills Powdermill Lane Waltham Abbey, Essex EN9 1BN United Kingdom Phone: +44 1992 656 631, Fax: +44 1992 656 700 e-mail: asify@pennwell.com Europe and Middle East Classifieds/Literature Showcase Account Executive Jenna Hall 1421 S. Sheridan Rd. Tulsa, OK 74112 Phone: 918-832-9249, Fax: 918-831-9834 email: jennah@pennwell.com
38 Ametek Process Analytical

www.ametekpi.com
Mobil Industrial Lubricants

mobilindustrial.com
4 6 22
Areva
us.areva.com/atrium
N B Harty General Contactor Inc NEM BV

www.nem-group.com
Ashross
ashross.com
Babcock Power Inc.

babcockpower.com
36 New York Blower Company

nyb.com
Bechtel 49 11 Bete Fog Nozzle Inc

www.bete.com
32 Norit Americas Inc

norit-americas.com/extra
8 48 26
PCC Energy Group

pccenergygroup.com
Brand Energy and Infrastructure Services

www.beis.com
PennWell GEN-HUB
generationhub.com/trial
Phillips 66 Lubricants
phillips66lubricants.com
39 Buckman
buckman.com
66 47 24 41 18 40 45 52
POWER-GEN WEEK
powergernerationweek.com
12 25 24
Carver Pump Company

www.carverpump.com
50 ProEnergy Services LLC

proenergyservices.com
Clearspan Fabric Structures

wwwClearSpan.com/ADPWRE
Railserve, Inc.
www.RailserveLEAF.biz
COAL-GEN
coal-gen.com
Reliable Turbine Services

www.reliableturbineservices.com
31 Combustion Components Associates

www.cca-inc.net
52 Renewable Energy World

powergernerationweek.com
13 16 46 23 19 41 42 43 28 40 15
Corrpro
www.corrpro.com
25 29 77 39 33 69 71 72 46 67 27 58 63 47
33 Rotork Controls Inc

www.rotork.com
Elster
www.elster-instromet.com
20 10
Roxul Inc
www.roxul.com
Enercon Services Inc

enercon.com
Santee Cooper
www.santeecooper.com/wpsale
Fibrwrap
www.fibrwrap.cpm
30 SEI Group
www.southernenvironmental.com
Fluor Corp
www.fluor.com
2 5 17 44
Siemens Ag
siemens.com/energy/controls
GE Haldor Topsoe AS
www.topsoe.com
SMA America LLC

www.SMA-America.com
www.ge-energy.com/energysavings
Stanley Consultants Inc

www.stanleyconsultants.com
Harco
harcolabs.com
The Society for Protective Coatings 73

sspc.org
Hydratight
hydratight.com/nuclear
34 Volvo Penta of the Americas

www.volvopenta.com
56 45 C2
Hydrolox
hydrolox.com
27 1
Weg Electric Motors

www.weg.net/us
Kiewit Power Inc

kiewit.com
Westinghouse Electric Co
www.westinghousenuclear.com
35 Martin Engineering
martin-eng.com
37 Matrix PDM Engineering 29 Membrana

liqui-cel.com
88
Advertisers and advertising agencies assume liability for all contents (including text representation and illustrations) of advertisements printed, and also assume responsibility for any claims arising therefrom made against the publisher. It is the advertisers or agencys responsibility to obtain appropriate releases on any items or individuals pictured in the advertisement.
www.power-eng.com
SpiralAir Nozzles are nely atomized full cone sprays available in a range of spray angles
BETE... highly efcient and reliable nozzles for all your power generation challenges.
TH Nozzles Large free passage with the most uniform liquid distribution
Meeting the demands for cleaner, more efcient operations

For over 50 years, BETE has been recognized as the leader in spray nozzle design and innovation for the power industry. BETEs technological advancements have revolutionized nozzles used for atomizing, evaporation, cooling, misting, and fogging. Achieve higher spray nozzle efciency and reliability using BETE nozzles.
Performance Through Engineering

TF Nozzles provide an exceptional clog-resistant spray for cooling gases
BETEs Application Engineers are known for their ability to nd creative solutions to difcult spraying challenges. As specialists in uid ow, BETEs engineers design everything from individual spray nozzles to lance assemblies that can be integrated into existing processes. From engineering concept to delivery, we are dedicated to producing the highest quality nozzles.
BETE. Your strategic partner for engineered spraying solutions.
Made in the USA
TFXP Nozzles for re protection and evaporative cooling with the largest free passage which are full cone and are clog resistant
MaxiPass Nozzles provide maximum free passage to deliver atomized slurry into the absorber tower with a nely atomizing full cone spray
TH Nozzles patented geometry designed to give the most uniform liquid distribution around the periphery of the spray
BETE Fog Nozzle, Inc. T(413)772-0846 F(413)772-6729 www.bete.com

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Were Not Exaggerating. Our Boilers are something to brag about.

A Q&A WITH AREVA CEO MIKE RENCHECK

EXECUTIVES DISCUSS THE FUTURE OF COAL

the magazine of power th we generation ti

A Breakthrough re for Clean Coal

July 2013 www.power-eng.com

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