DEMONSTRATE REGULATORY COMPLIANCE AND COMMERCIAL VIABILITY WITH CONFIDENCE.
Breen Energy Solutions provides a broad range of technologies and services to the fossil fuel power and industrial markets to help end users manage their emissions and the Balance-of-Plant (BOP) impacts resulting from their emissions control systems.
DRY SORBENT INJECTION SYSTEMS
As coal-fired power plants face increased environmental regulations amid commercial viability concerns, a growing number of plants have adopted Dry Sorbent Injection (DSI) as an answer to compliance and efficiency requirements. Fortunately, or unfortunately, there are as many sorbents and injection locations as there are issues. In an effort to understand and quantify the performance of a selected sorbent process, individual plants often execute on-site demonstrations of the process. These demonstrations are expensive to mobilize and implement, and an improperly designed or executed program can yield conflicting results.
Breen is uniquely positioned to provide sorbent and process independent guidance through this difficult process. Our experience with multiple coals, plant configurations, sorbents and gas chemistries allows us to assist our customers with:
- Baseline/Characterization of existing plant SO3 and HCl levels throughout the gas stream
- Assistance in proper Sorbent Selection based on plant-specific process and performance drivers
- Injection Location and Bias Determination to provide maximum condensable capture without negative impact on SCR, air heater and particulate control systems
- Process Optimization and Credible Evidence Demonstration to provide hard evidence of both system operating costs and compliance assurance through normal plant operating variations
Each plant is unique in its ability to generate and dissipate SO3 compounds. Breen’s field engineering staff, using our patented condensable measurement technology — the Breen Probe — monitors the level of SO3-based material at the economizer outlet, SCR outlet, air heater outlet and ESP/FF outlet during extended periods of normal plant operation. Comparing this information with plant historical data for such variables as boiler load, excess O2, boiler cleanliness and SCR NOX/NH3 distribution provides a solid understanding of how and where sulfate compounds evolve in the plant gas stream.
Understanding the impact of normal plant operations on sulfate condensables is the first step toward designing a suitable sorbent injection process to control it.
Injection Location and Bias Determination
Breen Energy has a fleet of fully staffed and instrumented temporary hydrated lime injection systems designed to provide a high level of flexibility in terms of injection location and control. Our equipment is suitable for injection rates as low as a few hundred pounds/hour of hydrate to as much as 20,000 pounds/hour. Each system has four individually controlled feed systems, each capable of feeding controllable split trunk lines.
Using this process, sorbent material can be individually metered/biased/monitored to eight simultaneous injection locations. This allows determination of the proper amount of sorbent, as well as the proper distribution of that sorbent between functional injection locations for varying plant operating conditions (load, SCR performance, fuel sulfur, etc.).
Process Optimization and Credible Evidence Development
Once the sorbent injection locations/splits have been determined, Breen program management works with plant engineering and environmental staff to develop an optimized injection process complete with predictive emissions feedback.
This last step is critical because it provides the plant with continuous credible evidence that its sorbent injection process is in compliance with state and federal emissions requirements. The lack of this step often forces the plant to inject minimum fixed amounts of sorbent, regardless of changes in plant conditions. This forced minimum often causes both cost and balance of plant issues that can lead to landfill, water and process performance problems over time.