5) Ammonia Supply Systems For SCR

AmmoniaSupplySystems
forSCR
WPCA/DukeNOxSeminar
June7,2005
Dr.NormanC.Foster
WhyisAmmoniaRequired?
Ammonia(NH3)istheReducing
AgentforNOx
2NH3 +2NOx+ O2
Copyright2005ChemithonEnterprises
2N2 +3H2O
N0x ControlUsingAmmonia
NH3 InjectionSystemExample
TypicalAmmoniaRequirements
1005000lb/hofAmmonia
SourcesofAmmonia
AnhydrousAmmonia
AqueousAmmonia
Urea
AnhydrousAmmoniaProperties
MolecularWeight 17.03
Vaporis40%lighterthanair
Flammablewithinnarrowrange16
25%inair
Highheatofvaporization
Usedasrefrigerant
Approximately588btu/lbNH3
CharacteristicsofAnhydrous
Ammonia
LiquidwhenCompressedorCooled
StoredasaLiquidunderpressure
1Ft3 ofLiquidproduces865Ft3 of
100%pureNH3Gas
1Ft3 ofLiquidmustbedilutedwith
2,900,000Ft3airtoreduce
concentrationbelow300ppm
AnhydrousAmmoniaVapor
Pressure
350
300
PSIG
250
200
150
100
50
0
-50
50
TEMPERATURE F
100
150
EffectofPressure
WhenliquidanhydrousNH3 is
releasedfromstoragepressureitcools
Adropfrom200psig(100oF)to
atmosphericpressurecoolsammonia
to28oF.
AnhydrousAmmoniaHazards
EPARegulatedToxicSubstance
40CFRParts9and68
Requiresstorageat250psigor
Refrigeration
OSHApoisonousgaslist
HazardsinTransportationandStorage
Singletankertruckspill 20acrelethal
area
AnhydrousAmmoniaRegulatory
Requirements
Transport,Handling&IncidentReporting:49CFR171180
ProtectionofEmployees:29CFR1910,OSHA&DOL
IncidentReporting:49CFR1904
EnvironmentalReleases: 40CFR1799,FWPCA1972,
CWA1977,CWA1978,TSCA1976,
CERCLA1980,SARA1986
EmergencyPlanningandCommunityRighttoKnow:
EPCRA1986
StorageTanks&Vessels:ANSIK61.1,ASMESECVIII,Div1
ProcessPiping:ANSIB31.3
AmmoniaExposureLimits
Least perceptible odor
Readily detectable odor
No health impairment for prolonged exposure
General discomfort; no lasting health effect for short
exposure
Severe irritation; no lasting health effect for short
exposure
Dangerous less than hour exposure may be fatal
Rapidly fatal
Immediately fatal
From Anhydrous Ammonia Pamphlet G-2 Seventh Edition, Compressed Gas
Institute
5 ppm
20 50 ppm
50 100 ppm
150-200 ppm
400 700 ppm
2000- 3000 ppm
5000- 10000 ppm
Over 10000 ppm
UncontrolledAmmoniaReleases
AmmoniaLiquidrefrigeratesandforms
lethalfogofWater/NH3
TypicalWater/NH3 Cloudiswhitebut
maybeinvisible
Water/NH3 CloudsMoveUnpredictably
withAirMovement
Water/NH3Cloudsareheavierthanair
RespondingtoanNH3Release
GetoutoftheArea
NotifyEmergencyResponseStaff
IsolateAmmoniaSupply
Fogareawithwaterspray
AnhydrousAmmoniaSystem
Ammonia
Un-Loading
Ammonia
Vaporization
Ammonia
Storage
Ammonia
Dilution
Safety Spray System
Ammonia
Pumping
Ammonia
Injection
AnhydrousAmmoniaSystem
Process
Ammonia is received by Tank Truck

Unloaded using Unloading Bulkhead and
Unloading Compressor System to Storage
Ammonia is pumped or flows by pressure from
storage to the vaporizers
The operating vaporizer evaporates ammonia
Ammonia vapor is piped to NH3 metering/Dilution Air
Skids
Ammonia is metered based on demand from SCR
Ammonia is metered into air and supplied to the

Ammonia Injection Grid just upstream of the SCR.
AnhydrousNH3SystemUnit
Operations
Safety Systems
N2 Supply System
Unloading Bulkhead
Unloading Compressor System (optional)
Ammonia Storage Tanks
Ammonia Pumping System
Ammonia Vaporizers
Ammonia Metering and Dilution Air Systems
Plant / Instrument Air Supply System
Control System
AnhydrousAmmoniaSafety
Systems
NH3 Sensor/Fog Water Areas
NH3 Storage Tank Area
Equipment Room
Unloading Area
Ammonia Metering Dilution Air Skids (3)
Safety Equipment
Emergency Stops (E-Stops)
Safety Shower Eyewash Stations
NH3 Sensors
Local Alarm Panels w/ Flashing Beacon & Horn
Fog Water Systems
EmergencySpraySystem
NitrogenPurgeSystem
Why nitrogen (N2) Purge
Used to purge
unloading arm connections.
Eliminates NH3 from
connections.
Eliminates O2 and H2O from
entering the system.
Equipment
N2 cylinder rack
Pressure reducing valve & pressure relief valve
Pressure gauge and switch to alarm is low
pressure supply.
AmmoniaUnloadingBulkhead
Equipment
Two Unloading Arms: Vapor & Liquid
Automated liquid line valve, Emergency
vapor line valve.
Liquid line flow switch & vapor line
pressure transmitter
AmmoniaStorageTanks
Equipment
Ammonia Storage Tanks, Rated
265 to 300 Psig
Level, Pressure, and Liq.
Temperature Transmitters
Level Switch, Pressure safety
valve manifold
Piping system to select fill and
supply tank.
NH3 LoadingandStorage
AmmoniaPumpingSystems
Equipment
Two Side Channel Pumps,
one operates, one as inline
spare
Pressure Transmitter,
Piping and automatic valves
to select supply tank
NH3 Pumping
AnhydrousAmmoniaTank
AnhydrousAmmoniaVaporizers
Equipment
Vaporizers may use either Steam,
Electricity or Hot Water
Two Vaporizers, one operates,
one as inline spare
NH3 Pressure, NH3 and Outlet
water Temperature Transmitters,
Piping and automatic valves to
select vaporizer
NH3 Vaporizing
AnhydrousStorageTankandVaporizer
Skid
VaporizerSkidControlPanels
LiquidAmmoniaPiping
Do not block in piping system and components when full of liquid
ammonia. Thermal expansion of liquid ammonia will cause extremely
high pressures. Ball
Liq. NH3 Volume vs Temperature
valves for
anhydrous
2.9
ammonia have
vented balls.
Hydrostatic relief
valves on
piping system
Volume (Ft^3/100Lbs)
2.85
2.8
2.75
2.7
2.65
2.6
2.55
-100.00
-50.00
0.00
50.00
Temperature (F)
prevent over
pressurizing.
100.00
150.00
AmmoniaMetering&DilutionAir
System
Equipment
Two dilution air blowers, one operates,
one as inline spare
NH3 and Air: Flow, Pressure &
Temperature Transmitters
Piping and automatic valves to isolate
NH3 vapor and to select the operating
blower
AmmoniaMetering&Dilution
DilutionAirSystem
AqueousAmmonia
EPARegulatedToxicSubstance
Highenergycoststoevaporatewater
588BTU/lbNH3
1000BTU/lbWater
Additionalheatrequiredtopreventcondensation
Concentrationmustbelessthan20%
TransportingandEvaporatingwater
HigherAmmoniacosts
AqueousAmmoniaSystem
SimilartoAnhydrousAmmonia
LowerPressureStorageTanks
FewerSafetyRequirements
Usesmuchmoreenergytoevaporate
Water
EnergyRequiredtoEvaporateNH3
Ammonia
Concentration
lbs
NH3
Lbs
Water/
lb NH3
BTU/
lb NH3
Anhydrous
NH3
28% NH3
2.57
3,159
19.5% NH3
4.13
4,716
588
AqueousAmmoniaStorageVessel
PumpSkid
Urea
Safenontoxicstablematerial
Primaryactivecomponentinfertilizer
Readilyavailable
Deliveredcostsperpoundofammonialess
thanaqueousammonia
Typicaldeliveredcostsabout1.5to2times
anhydrousperpoundofammonia
ChemithonSafeDeNOx
UreatoAmmoniaProcess
Urea
Urea
Feed
System
SafeDeNOx
Reactor
System
Urea
Storage
System
Steam
Urea
Feed
System
SafeDeNOx
Reactor
System
Ammonia
to
Process
Scrubber
System
DryUreaStorage&Unloading
SILO
SILO
SILO
UREA
FROM
TRUCK
DRY AIR
TO
TRUCK
AIR
DRYER
UREA
TO
SUPPLY
SYSTEM
SILO
DryUreaStorage
Truckcandeliverupto35tonsper
load
Railcandeliverupto100tonsper
load
1,100poundsofammoniapertonof
urea
Mosteconomicalformtostoreurea
DryUreaStorageBenefits
Loweroperatingcost noheated
tanks
Lowerdeliveredcost
Nospillcontainmentrequired
BatchUreaDissolving&Storage
FI
FE
RECYCLE
H.E.
UREA
FROM
TRUCK
STEAM
UREA
DISSOLVING
TANK
FIC
CONDENSATE
RECYCLE
PUMP
CONDENSATE
MAIN STORAGE
TANK
UREA FEED
PUMP
FE
SC
FIC
FE
STEAM
CONDENSATE
UREA
TO
REACTOR
ContinuousUreaDissolvingStep
Canbecontinuousorbatch
Requiresdensitycontrol
Mixingtanksareneeded
RequiresDIwaterserviceandstorage
Bestchoiceforsmallersystems
ContinuousUreaDissolving
System
UREA
FROM
STORAGE
CONDENSATE
UREA
DISSOLVER
STEAM
CONDENSATE
STEAM
SC
FIC
CONDENSATE
FE
UREA
PUMP
UREA
TO
REACTOR
UreaMelterSystem
UREA
FROM
STORAGE
UREA
MELTER
STEAM
CONDENSATE
STEAM
SC
FIC
CONDENSATE
FE
UREA
PUMP
UREA
TO
REACTOR
UreaMelterSystem
Nodeionizedwaterneeded
Ureameltsat271F(133C)
Moltenureahasalowviscosityandis
easilypumped
Similartosulfur
Chemithonhasover40yearsofexperience
inmeltingandhandlingsulfur

SafeDeNOx
ReactorSystem
AMMONIA
PRODUCT
UREA
FROM
FEED
PUMPS
FIC
FIC
STEAM
FE
FE
CONDENSATE
CONDENSATE
FIC
STEAM
FE
STEAM
UREA
REACTOR

SafeDeNOx ProcessReactions
UreaDecomposition
(NH2)2CO+3H2OCO2 +2NH4OH
urea
watercarbonammonium
dioxidehydroxide
NeutralizationofMAP
2NH4OH+2NH4H2PO4 2(NH4)2HPO4 +2H20
MAP
DAP
DecompositionofDAP
2(NH4)2HPO4 2NH4H2PO4 +2NH3
DAP
MAP
ammonia
vapor

SafeDeNOx OverallReaction
Atequilibriumallthreereactions
occursimultaneously
Overallreaction
(NH2)2CO+H2O CO2 +2NH3
urea
water
carbonammonia
dioxidevapor
SafeDeNOx CatalystInformation
MixtureofMonoAmmoniadi
hydrogenPhosphate(MAP)andDi
AmmoniahydrogenPhosphate(DAP)
(excess)
Itisawhite,watersolublecrystal,
easytoaddthroughthefeedsystem.
3,300lbs(1,500kg)ofcatalystfor1,400
lb/hr(635kg/hr)reactor

SafeDeNOx ReactorSystem
Usesselfregeneratingcatalysttoaccelerate
thereaction
Monoammoniumphosphate(MAP)
Catalystallowsnearstoichiometriclevels
minimizesenergyrequirements
Approximately3,500BTUs/lb(1,945kcal/kg)
NH3
50% Urea solution Feed Rate

(lbs/hr)
SafeDeNOx
ResponseRate
400
350
300
Ammonia Flow
Ammonia Se t Point
Ure a fe e d rate
90% Response rate within 5

Minutes
For a 55% change in demand.
250
200
150
100
50
0
0
10
15
Time (minutes)
20
25
30

SafeDeNOx
ResponseRate
400
Ammonia
Set Point
Urea Feed Rate
Flow rate (Ure a lbs/h r)
350
300
250
200
150
100
50
0
0
20
40
60
80
Time (min.)
100
120
140
160

SafeDeNOx
Benefits
Respondsquicklytochangesin
ammoniademand
Selfregeneratingcatalyst
significantlyreducesurearesidence
time
Constantammoniaconcentration
(minimizesslip)
StartupofFirstCommercial
SystemReliability 98%Average
Percent Availability
Plant Karn 1 & 2 Availability

100
98
96
94
92
June
July
August
September
800lb/hr(360kg/hr)SafeDeNOx
System
UreaStorageandHandling
UreaFeeders&Melter
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5) Ammonia Supply Systems For SCR

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5) Ammonia Supply Systems For SCR

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AmmoniaSupplySystems

Safety Spray System

Ammonia is received by Tank Truck

Ammonia is metered into air and supplied to the

50% Urea solution Feed Rate

90% Response rate within 5

Flow rate (Ure a lbs/h r)

Plant Karn 1 & 2 Availability

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