How to Improve Air Pollution–Control with CFD- Modeling

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Siemens Industry Software GmbH Digital Factory Division

However, the GSG technology produced a significant improvement compared to traditional turning vane techniques. Fuel Tech was contracted by KCP&L in 2012 to perform a thorough CFD optimization and EFD validation study, and, later, to provide equipment and equipment performance guarantees based on the results of this study.

The unit was restarted in 2013 with a notable reduction in catalyst pluggage due to ash precipitation and the retrofit has been deemed a large success. According to the paper by KCP&L engineer Scott Heideman (Heideman, 2013) the GSG has resulted in annual operational savings of $5 million. It is notable that the next catalyst layer replacement for this unit is not budgeted until 2019. This means that only one layer needs to be replaced over the next seven years, which is a major improvement compared to eight layer replacements over the course of the last five years.

Fuel Tech and the Birth of I-NOx

Integrated NO_x Reduction, or I-NO_x, is an advanced NO_x removal technology that successfully addresses all of the challenging aspects of an SCR unit and takes it to a higher level of performance while maintaining a low capital cost. This technology was first introduced by Fuel Tech to be a combination of their CFD-guided staged approach for NO_x reduction including advanced combustion modifications consisting of Low-NO_x-Burners (LNB) and Over Fire Air (OFA), and post combustion de-NO_x approaches including Selective Non-Catalytic Reduction (SNCR), and Selective Catalytic Reduction (SCR). 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.

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