Breen provides a wide range of cost and process improvement technologies and services for the fossil fuel fired steam and power generation industry. Breen’s products and services are broadly classified in three categories, namely Acid Gas solutions, Sorbent Injection solutions and Combustion products. Most of these products and services are applicable to this industry.
Acid Gas solutions
AbSensor – Sulfuric Acid/SO3/Dewpoint Measurement
All fossil fuels, to some degree, have sulfur which oxidizes to SO2 and then to SO3 within the combustion process. The SO3 fraction further combines to form H2SO4 (Sulfuric Acid) within the flue gas. The sulfuric acid may further combine with elements such as NH3 (Ammonia), Na (Sodium) to form even more corrosive condensates.
Following are some of the negative impacts from Sulfuric Acid / Sulfur condensates:
- Corrosion in ductwork and equipment
- Fouling of equipment such as tube bundles and air preheaters
The impact of such issues is higher operational and maintenance costs, greater equipment wear and tear, increased downtime and reduced efficiencies. Operators therefore tend to run their plants at higher flue gas temperatures to prevent condensation and corrosion which has a significant impact on heat rate / efficiency.
The patented Breen AbSensor measurement system can measure the presence, concentration, species and dewpoint of sulfuric acid and other sulfur condensates. This information can then be used in operational decision making, process optimization, efficiency improvements and other solutions to these problems such as mitigation of these compounds using Alkali injection.
Thermap Air Preheater Model
In the case of Air Preheater fouling, it is critical to understand exactly where in the Air Preheater the fouling deposits are accumulating in real-time. The Breen Thermap thermodynamic air preheater model combined with the deposition depth model, can accurately predict in real-time the depth & location of such deposits. This information can then be used in operational decision making and mitigation control processes such as Alkali injection.
DySC Air Preheater Sootblowing System
Sulfuric Acid and other Sulfur condensables deposit on the Air Preheater baskets and are cleaned using air or steam sootblowers. These sootblowers typically operate using a timer algorithm where the sootblower lance is indexed from the perimeter to the trunnion of the Air Preheater in pre-determined increments, pausing at each index position for a set amount of time to allow the sootblowing media to clean the basket passages. While this process is fairly effective, it is not fully effective towards the perimeter of the baskets, particularly in the face of tenacious deposits. This is because the velocity at which the baskets move relative to the sootblowing nozzle increases as one travels from the trunnion to the perimeter, with the perimeter velocity being as much as 5 to 10 times higher than the trunnion velocity.
The Breen Dynamic Speed Controlled (DySC) sootblowing system improves upon the traditional sootblowing techniques by adjusting the rotational speed of the air preheater in concert with the sootblower lance position to maintain an optimal velocity at which proper cleaning is guaranteed. The system combines electrical design, mechanical modifications and a controller algorithm to deliver improved performance.
Sorbent Injection Solutions
While Acid Gas Management solutions focus on the measurement and optimization of existing equipment and processes, Sorbent Injection Solutions focus on mitigation of pollutants. Sulfuric Acid and Sulfur condensables in the flue gas produced during combustion, can be mitigated using Alkali sorbents to protect against equipment and duct corrosion, air preheater fouling, as well as to reduce stack emissions resulting in a blue (acid) plume.
Breen provides the following Alkali Sorbent injection services and equipment:
- Calcium or Sodium based Alkali Dry Sorbent Injection (DSI) demonstrations
- Semi-Permanent Dry Sorbent Injection system rental, lease or sale
- Long-term operation of DSI systems
- DSI system maintenance and optimization
- DSI system redesign and upgrade
Mercury (Hg) emissions in power and industrial applications may be mitigated using Activated Carbon injection (ACI). Further ACI can be used for the mitigation of other heavy metals such as Selenium (Se) and Arsenic (As) among others, dioxins and furans.
Breen provides the following Activated Carbon Injection (ACI) services and equipment:
- Activated Carbon injection demonstrations
- Long-term ACI system rental, lease or sale (ACI-In-A-Box)
- Long-term operation of ACI systems
- ACI system maintenance and optimization
- ACI system redesign and upgrade
Breen provides the following combustion products for the efficient combustion of fossil fuels that allows for fuel flexibility, optimization of resources and pollutant emissions reductions.
TrueFire 3000, NFPA 85 Compliant Continuous Duty Igniters
The TrueFire 3000 line of NFPA 85 compliant continuous duty gas fired igniters provide for reliable ignition of the main burners, which utilize fossil fuels such as coal, oil, gas or other fuels.
The key features of these igniters are:
- Forced draft combustion air for ignition and cooling
- Integrated sparking
- Integrated Ionization flame detection
- Continuous duty
- Wide range of acceptable pressure and flow for fuel and air
The design of these igniters makes it impervious to furnace pressure changes thereby improving reliability. The integrated sparking and flame detection technology eliminates the need for additional furnace penetrations and equipment greatly de-cluttering the burner/furnace face, improving reliability, accessibility and safety. Additionally this reduces maintenance and support costs. The forced air combustion air from dedicated blowers eliminates the need for retraction mechanisms, thereby improving reliability, availability, burner/furnace face decluttering. These igniters are continuous duty thereby making them suitable for low-load stabilization. These igniters are suitable as Class 1, 2 or 3 igniters.
TrueFire 4000 – Dual Orifice Co-Firing (DOC) NFPA 85 Compliant Continuous Duty Igniters
Building upon the design features of the TrueFire 3000, NFPA 85 Igniters, the TrueFire 4000, DOC igniters provide the capability to continuously fire as much as 2+ times the fuel as the primary Class 1 Igniter. This means that for a typical 20 MMBtu Class 1 igniter, the DOC igniter can provide an additional 45 MMBtu through the secondary orifice, thereby providing a total heat input capability of 65 MMBtu.
The key benefits of the TrueFire DOC igniters are:
- Capability to Co-Fire as much as 65 MMBtu simultaneously with the primary fuel such as coal, oil or other. Provides fuel-flexibility, resource optimization and cost optimization.
- Reduction in minimum stable load to as little as 20% of nameplate load by allowing operation with one coal mill, with the gas igniters providing supporting combustion
- Lower mill maintenance costs
- Reduced fuel costs during low load demand/pricing
- Reduced cycling, startup/shutdown
- Burning a higher percentage of lower-sulfur natural gas leading to:
- Reduced SO2 emissions. Reduction in SO2 mitigation costs (scrubber or DSI)
- Reduced SO3 emissions. Reduction in SO3 mitigation costs, DSI, reduced air preheater fouling, reduction of SCR MOT (improved NOx performance)
- Reduced ash. Better ESP performance.
- Ability to meet SO2 emissions goals with Lime DSI without a scrubber
- Reduced NOx emissions
- Reduced Hg emissions allowing marginal units to comply with MATS. Reduced cost of ACI and/or Hg Additives
- Reduced CO2 emissions
Fuel Lean Gas Reburn (FLGR) for NOx reduction
FLGR is an industry proven technology that utilizes Natural gas as a reburn reagent to reduce NOx emissions. In traditional boilers without Low NOx burners / Overfired Air (LNB-OFA), FLGR can provide as much as 30% +/- NOx reduction with injection of Natural Gas up to 10% heat input. In boilers with LNB-OFA, FLGR can provide as much as 20% +/- NOx reduction with injection of Natural Gas up to 10% heat input.
The above technologies by themselves or in various combinations provide the necessary tools to utility and power operators to meet the increasing market and environmental demands as they navigate the balancing act between economic viability and regulatory compliance.