Partial List of Past SAVvy Engineering Projects
- 1. 1 Some recent SAVvy Engineering projects include the following; Advanced Burner Technologies and Nagel Rice & Mazie Expert witness in litigation involving contract for low NOx burners. Contacts: Joel Vatsky 908-470-0470 and Jay Rice 975-535-3100 American Electric Power Service Corporation Annually renewed contract to provide engineering design input and testing technical support for all combustion related NOx control projects. Design and implementation of OFA system (including cyclone burner modifications), for Indiana and Michigan Power’s Tanners Creek Unit 4, 500 MW supercritical cyclone fired unit. Achieved approximately 80% reduction in full load NOx emission rate. Design and implementation of OFA system and burner zone modifications for Kentucky Power’s Big Sandy Unit 1, 265 MW opposed wall, pulverized coal fired unit. Unit achieves an additional 30% reduction in NOx emissions. Riley Power’s CCV low NOx burners installed in 1998. Project also included development and application of hopper purge air. Design and implementation of OFA system (including cyclone burner modifications), for Columbus and Southern Power’s Conesville Units 1 and 2, 2x125 MW cyclone fired units. Achieved approximately 65% reduction in full load NOx emission rate. Design and implementation of burner modifications for Indiana and Michigan Power’s Tanners Creek Units 1-3 (2x150 MW and 1x200 MW), Ohio Power’s Philip Sporn Units 1-4 (4x150 MW), and Appalachian Power’s Kanawha River Units 1and 2 (2x200 MW) and Clinch River Units 1-3 (3x200 MW). All are roof-fired steam generators, originally designed by B&W. Original low NOx combustion system was designed and patented while an AEP employee. Recent modifications were to accommodate deeper staging levels for further NOx emission rate reductions. Provide technical review of Alstom LNCFS Level II NOx control installation for Columbus and Southern Power’s Conesville Unit 4, 800 MW. Developed minimal cost cyclone scroll burner modifications, including CFD modeling supervision, to mitigate carbon in flyash and carry-over of granular ash particles to electrostatic precipitator at Ohio Power’s Kammer Units 1-3, 3x210 MW front wall cyclone fired. Data to date indicates that LOI reduced by a third at consistent cyclone staging and NOx emissions. Granular ash carry-over has been reported to be minimal and slag coating within the cyclone barrels has been notably improved. On-site technical and analytical support of NOx and combustion optimization efforts at AEP’s eastern fleet, including cyclone fired units and pulverized coal fired units with Riley Power CCV, Foster Wheeler CF/SF and CF/IFS, B&W XCL-hybrid, and in-house designed roof-fired
- 2. 2 low NOx combustion systems, with and without OFA and on a range of eastern bituminous and western sub-bituminous coals. On-site technical and analytical support of NOx and combustion optimization efforts at AEP’s western fleet, including pulverized coal fired units with Foster Wheeler CF/SF and CF/IFS, ABT Opti-flow and T-fired low NOx combustion systems, with and without OFA with an emphasis on slagging control with western sub-bituminous coals. Contact: John J. Letcavits 614-716-3287 Bechtel Power Technical support for burner modifications at Louisville Gas & Electric’s Trimble County Unit 2 to alleviate burner deposition and coking. Effort expanded to duct modifications to produce improved secondary and primary air flow measurement capabilities, reduce pressure drop, improve flow distributions and develop operational changes to mitigate furnace exit gas temperature excursions and improve fuel flexibility. Contact: Mel Watkins 240-793-4490 Cinergy (Now Duke) Contracted to provide assistance regarding low NOx burners on Miami Fort Unit 7. Contacts: Doug Ginn 513-313-5248, Chris Huber or Marty Schafer 812-949- 6448 or Jason Clanin 513-467-5874 Dayton Power & Light Contracted to provide combustion, fuel and steam generator island oversight and support for the DP&L coal fired fleet. Projects have included fuel switching, low NOx combustion system retrofits, and operational modifications to increase unit turndown capabilities. Pulverizer modifications to improve air flow control and pulverizer turn-down without need for supplemental fuels. Combustion testing and evaluations for optimized efficiencies and emission controls. Air heater air and gas side leakage testing and equipment analyses. Evaluation and development of alternatives for gas temperature control for selective catalytic reduction catalyst operation. Modification of pulverizers, coal feeders and primary air flow indication. Also intimately involved in renewable energy projects, including biomass co-firing, CO2 sequestration demonstration projects, and the burning of engineered fuels. Contact: Mark Least 937-549-2641 (ext. 5817) Electric Power Research Institute Contracted to support the efforts of the Waterwall Wastage Interest Group and the Pulverizer Interest Group. Contacts: Anthony Facchiano 650-855-2494 and Jose Sanchez 650-855-2580
- 3. 3 FMC Corporation Design modifications provided for both Westvaco and Granger facilities to improve NOx emission controls without detrimental impact to CO emissions for industrial MACT compliance. Contact: Kelly Radtke 307-872-2244 Grand Haven Board of Light and Power Initially contracted to design an overfire air system for Sims Unit 3 to address Title IV requirements in 2000. Later (2003) contracted to evaluate bid specifications and bids to upgrade milling system, burners and advanced overfire air installations. Also hired in 2004/2005 to review post installation design and testing efforts for potential deficiencies in design details. Flaws in OFA duct details found to introduce excessive pressure drop. Primary air fans also determined to be operating near peak of performance curve, creating considerable flow sensitivity to pressure fluctuations. Contact: Daniel Bush 616-842-6355 Hoosier Energy Cooperative Proposed combustion modifications to mitigate CO emissions and improve NOx control at Merom Station. Adjustments to burners to improve oil lighter and flame scanner operation and improve combustion efficiency at Ratts Station. Contact: Stephan Martin 812-935-4709 Indianapolis Power & Light Support of legal matters involving pulverizer puffs at South Harding Street Station. Update/develop standard operating practices for pulverizer related operation. Contact: Norman (Tom) Funk, Krieg Devault Legal, 317-636-4341 LP Amina Providing technical support and product development for LP Amina in China for application of NOx emission reductions and performance enhancements. Projects to date have included YiXing Units 8 and 9 separated overfire air addition and burner modifications, ShaoGuan Unit 10 and XingTai separated overfire air addition and burner modifications. Development of static external classifier for improved efficiency and low differential pressure on ball tube mill applications (patent pending). Development of new static classifier design for vertical spindle mills to provide improved classifier efficiency and reduced differential pressure (patent pending). Linking of calcium carbide and electric energy production utilizing cyclone furnaces (patent pending). Contact: William Latta 86 10 64107220
- 4. 4 Nalco-MobotecUSA Inc. Contracted to evaluate the impacts of staging and the application of Nalco- MobotecUSA’s ROFA system on the burner zone combustion and provide options to mitigate any negative impacts for Allegheny Power’s Armstrong Station, Nevada Power’s Reid Gardner Unit 4, Progress Energy’s Lee Unit 2 and Bremo Bluff Unit 4, Hoosier Energy’s Ratts Station, AES’s Beaver Valley Units 2-4, Minnesota Power And Light’s Boswell Energy Center Units 1 and 2, Basin Electric’s Leland Olds Station, Smurfit-Stone Container Corporation’s Ontonagon Unit 1, Rochester Public Utility’s Silver Lake Unit 4, BOT Elektownia Opole S.A.’s Unit 3 and others. Contacts: Jamie Fessenden 925-935-2500 (ext. 17), Mark Shilling 919-291-1216 or Dr. Brian S. Higgins 919-465-3830 NiSource (NIPSCo) Review burner and OFA design provided by Burns & McDonnell and Power & Industrial for R.M.Schahfer Generating Station Unit 15. Provided recommendations for burner modifications and OFA system to provide estimated 5-10 and 30% incremental reductions in NOx emissions, respectively. Also reviewed SNCR trim provided by Fuel Tech and proposed testing to further optimize. Contact: John Loden 219-956-5115 Reaction Engineering International Involved with several projects involving the CFD modeling of steam generators for the purpose of reducing emissions and/or erosion. Provided input into appropriate modeling inputs and evaluation of modeling results. Supported development and application of overfire air to Allegheny Energy’s Willow Island Unit 2, cyclone fired unit. Contacts: Bradley Adams 801-364-6925 (ext. 18), Marc Cremer 801-364-6925 (ext. 14) or Kevin Davis 801-364-6925 (ext. 23) Recycled Energy Development (RED) Investigated cyclone fired units at Kodak Park, Rochester, NY and provided recommendations to improve unit operations and turn-down capability. Contact: Eric Gottung 630-590-6045 Tennessee Valley Authority Performed technical evaluation of Paradise Unit 3 cyclone operation and OFA system to determine needs to further reduce NOx emissions while mitigating furnace corrosion potentials. Contact: Forrest Cunningham 370-476-4068
- 5. 5 Other less recent projects have included: Arizona Public Service (1999) Four Corners Unit 2 opacity ascendances due to combustion modifications: severe levels of unburned carbon in ash particularly during load cycling was producing very dark stack plume, visible for miles. This problem was attributed to the operation of the milling system producing end to end flow swings. This coupled with the segregation of the mill ends to the left and right side of the units during the burner modifications was creating corresponding excess air swings left to right on the unit. The rich conditions that resulted produced unburned char in the flue gas. With no electrostatic precipitator and the wet scrubber’s ineffectiveness in collecting the carbon, the dark plume conditions were produced. SAVvy Engineering was contracted to help evaluate the combustion problem and adjust burners to help mitigate the problem. Elevating the excess air in anticipation of load swings was recommended as a short term measure. Restoration of the milling system to help mitigate end to end flow swings from the ball tube mill were included in long term recommendations. This included restoration of heated air to the pocket/overshot feeders to minimize coal caking within the feeders, restoring the inlet crushers and pre-dryer and/or adding specified perforated inlet plates to the primary air supply ducts to improve measurement and balance of primary airflow to the two ends of the mill’ upgrade the original heart style classifier to centrifugal classifiers, and restore original coal conduit layout that blends any flow mal-distribution from a mill within the furnace. Contacts: Dennis Delgrosso 602-371-7260 or Duane V. Pilcher 505-598-8406 Consumers Energy (1999-2001) Contracted to provide technical support to Consumer Energy’s Title I NOx Compliance efforts. Scope of efforts were expanded into providing project engineering support for specific efforts related to B&W, Mitsui Babcock and Alstom scopes of supply, as well as, Black & Veatch balance of plant efforts for the Campbell Station. Contacts: Jim Pomaranski or Brian Low 616-738-3499 Michigan Municipal Electric Association (2000-2001) Contracted to provide technical support to the members of MMEA in their Title I compliance planning efforts as they pertained to both combustion related NOx emission controls and post combustion SNCR and SCR options. This included evaluation of the combined generating assets of the MMEA members to determine most cost effective compliance strategies and benefits potentially available through combined compliance efforts. Contact:
- 6. 6 American Electric Power (2000-2002) Provided technical support for counsel representing AEP versus EPA in litigation. Contact: Janet J. Henry 614-716-1000