Utility & Power Companies

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

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.