From the Laptop to the Smokestack: How Computational Fluid Dynamics Boost Environmental Performance

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It also includes the optimal use of highly effective flow distributors such as static mixers, custom designed Ammonia Injection Grids (AIG), and the employment of the GSG. The CFD analyses enabled engineers to proactively decide on what approaches to take during each step of the design phase.

There are many factors that contribute to achieve an optimal design. For example, knowing the continuum concentration distribution of NOx and NH3, the temperature profiles, and the velocity patterns within the system are critical. If the profiles are highly skewed, engineers could perform CFD analysis on the number of required mixers to achieve a homogenous distribution. If the profiles are relatively well distributed, a tunable AIG may suffice without the need for a mixer which increases pressure loss.

Furthermore, the GSG provides the optimally distributed uniform gas velocities into the catalyst where space is limited. With all of these upstream NOx removal technologies and flow distribution devices including AIG, static mixer, and Fuel Tech’s patented GSG technology, the SCR system can be fully optimized.

Computational Fluid Dynamics for a System Wide Approach

Each of these NOx reduction components is optimized by the extensive use of advanced Computational Fluid Dynamics which enables engineers to take a system–wide design approach. This results in considerable cost savings compared to going to ground with a traditional standalone SCR facility and trouble-shooting problem areas later as they arise.

I-NOx has been estimated to achieve de-NOx rates of up to 85 per cent at less than half the capital costs of stand–alone SCR. Installed costs are estimated to be in the range of $100–150 per kW for an I-NOX installation compared to $300 per kW for a full stand-alone SCR. In a coal-fired power plant in Hong Kong, many elements of I-NOX have been successfully implemented and helped the unit exceed all performance criteria.

Because of the successful achievement at this facility, Fuel Tech continues to receive more orders for complete I-NOx retrofits (combustion modification, SCR, and SNCR) from other facilities throughout the world.

Revolutionary Tools for Engineers

The rapid development of computer hardware and CFD technology has introduced a revolutionary tool for engineers that will help them in addressing all the complexities required for APC at power plants and industrial facilities. The result is a high performance pollution control system capable of meeting strict environmental regulations while maintaining low capital and operating costs.

* The author is Senior Manager at Fuel Tech

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