PSEG Fossil LLC NOx Reduction Technologies

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PSEG Fossil LLCNOx Reduction Technologies

• August 9, 2005

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Types of Electric-Generating Units

• Baseload
• Load-Following
• Peaking

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Baseload

• Units intended to operate continuously at full
  load
• High annual capacity factors
• Nuclear units, e.g.
• Hope Creek Unit No. 1
• Salem Units No. 1 2
• None of PSEGs fossil fuel-fired units in New
  Jersey are baseload

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Load-Following

• Unit operation and output vary with demand
• Low to Moderate annual capacity factors (60)
• Coal/Gas/No. 6 oil-fired steam boilers
• Hudson Unit No. 1 (water injection)
• Hudson Unit No. 2 (scheduled for SCR, baghouse in
  2007)
• Mercer Unit No. 1 (SCR since 2004 lb/MMBtu)
• Mercer Units No. 2 (SCR since 2004 lb/MMBtu)
• Sewaren Units No. 1, 2, 3, 4 ( 0.15 lb/MMBtu)
• Gas/distillate oil-fired combined-cycle gas
  turbines
• (all
• Bergen Unit No. 1 (DLNC, water injection)
• Bergen Unit No. 2 (SCR)
• Linden Unit No. 1 (SCR)
• Linden Unit No. 2 (SCR)

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Peaking

• Serve a unique purpose
• Low to extremely low annual capacity factors
• Satisfy PJM Requirements
• Energy on high demand days
• Grid reliability security
• Congestion management
• Primary Reserve
• Energy in
• Synchronous Condenser (Spinning Reserve)
• Secondary Reserve
• Energy in

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Peaking

• Gas/distillate oil-fired simple-cycle gas
  turbines
• General Electric (GE) LM6000
• aeroderivative (
• GE Frame 7EA
• industrial (
• Pratt Whitney FT4
• aeroderivative ( 0.15 lb/MMBtu)

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Low Load Day
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High Load Day
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Congestion Management

• June 22, 1999 PSEG Generation
• PJM Contingency lines B on K system split at hr.
  1554
• - PJM orders Essex 11 12 for contingency (4
  hrs.)

Nuclear
Steam Combined-Cycle
Simple-Cycle
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PSEG Peaking Turbines

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Capacity Factors (2001-2004)
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Unit Retirements Since 1990
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Unit Retirements Since 1990 (continued)
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PSEG Fossil Environmental Progress
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Generation NOx Emission Rates PSEG Combustion
Turbines
MWh (000)
lb/MWh
2,500
2.0
2,000
1.5
1,500
1.0
1,000
0.5
500
2000
2001
2002
2003
2004
Year
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Potential FT4 NOx Reduction Technologies

• Selective Catalytic Reduction (SCR)
• Dry Low NOx Combustors (DLNC)
• Light Oil Emulsification (LOE)
• Water Injection
• Others
• SCONOx, XONON
• Repowering/Replacement

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Selective Catalytic Reduction (SCR)

• Description
• Ammonia is injected into exhaust gas, which then
  passes through a catalyst reactor where elemental
  nitrogen and water are the products of the
  NOxammonia reaction
• NOx Reduction Potential
• 80 to 95

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Selective Catalytic Reduction (SCR)

• Applications
• Boilers (e.g. Mercer 12)
• Combined-cycle or cogeneration turbines
• Bergen 2, Linden 12 (NJ)
• Bethlehem Energy Center (NY)
• Lawrenceburg (IN)
• Simple-cycle turbines
• Tracy, Hanford, Henrietta (CA)
• Gas only
• Different duty cycle (
• SCR-equipped simple-cycle turbines are newer,
  originally designed with SCR
• Mixed track record, especially with oil-firing

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Selective Catalytic Reduction (SCR)

• Issues/Concerns
• Exhaust Gas Temperature
• Optimum range of conventional catalysts (650F to
  850F)
• FT4 exhaust gas temperatures (1,040F to 1,200F)
• Attenuation air to cool exhaust gas or
• High-temperature catalysts (e.g. Zeolites)
• Thermal Shock
• Rapid start-ups and shutdowns
• Oil Operation
• Sulfur compounds may poison catalyst
• Ammonia Storage Handling
• Increased PM2.5, PM10 emissions

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Selective Catalytic Reduction (SCR)

• Issues/Concerns
• Lost power output from back-pressure
• Space considerations
• New stacks
• Jeopardizes FT4 spinning reserve capability
• system reliability issues (PJM)
• 30 million/yr lost revenue
• Cost-prohibitive
• Several times more expensive than water injection
• Not a viable technology for FT4s

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Dry Low-NOx Combustors (DLNC)

• Description
• Combustor can design premixes air and fuel,
  creating a fuel lean combustion environment that
  reduces peak flame temperatures controls
  thermal NOx
• NOx Reduction Potential on FT4s
• 60 to 70

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Dry Low-NOx Combustors (DLNC)

• PSEG Experience
• In mid-1990s, DLNC pilot-tested on Edison FT4s
• Unreliable performance
• Combustor cans readily developed thermal stress
  cracks
• Dropped in favor of water injection
• Not a viable technology for FT4s

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Light Oil Emulsification (LOE)

• Description
• Water emulsified fuel lowers peak flame
  temperatures to reduce thermal NOx
• NOx Reduction Potential on FT4s
• 40
• PSEG Experience
• In early-1990s, LOE pilot-tested on Edison FT4s
• Oil firing only
• CO emission concerns
• Dropped in favor of water injection
• Not a viable technology for FT4s

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SCONOx

• Description
• A single catalyst oxidizes nitric oxide (NO) to
  nitrogen dioxide (NO2), then absorbs NO2 onto
  its surface, which is coated with potassium
  carbonate (K2CO3)
• NOx Reduction Potential
• 90 to 95

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SCONOx

• Issues/Concerns
• To date, used only on combined-cycle or
  cogeneration turbines
• Not commercially available on simple-cycle
  turbines
• Optimum temperature range 300F to 700F
• 2 to 3 times more expensive than SCR
• Not a viable technology for FT4s

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XONON

• Description
• A catalyst integrated into turbine combustors
  limits combustion temperatures thermal NOx
  formation
• Combustors are customized to the particular
  turbine by the original equipment manufacturer
  (OEM)
• Currently only commercially available from
  Kawasaki Gas Turbines-Americas on a small
• (1.4 MW) turbine
• Not a viable technology for FT4s

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Water Injection

• Description
• Demineralized (DM) water is injected into turbine
  combustion zone to reduce peak flame temperatures
  control thermal NOx formation
• System Components
• Water injection skids
• Metering pumps (1 per engine)
• DM trailer processing pad
• DM water storage tank
• Instrumentation Controls
• NOx Reduction Potential on FT4s
• 40

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Water Injection

• PSEG Experience
• Retrofitted on Edison Units No. 1, 2, 3 (24
  FT4s)
• Successfully operated since 1999
• Edison represents 35 to 45 of total FT4
  operations
• Estimated Cost 500k to 1 million per FT4
• Most FT4s dont run enough to justify the cost
• Unmanned locations (Bayonne, National Park)
  present additional difficulties

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Repowering/Replacement

• PSEG has been systematically repowering or
  replacing its electric-generating units since
  1990
• Cost-prohibitive
• Installed cost of new simple-cycle peaking
  turbines
• 500 kW (0.5 million/MW)
• Replace 200 MW 100 million
• Replace entire FT4 fleet 1 billion
• System reliability issues (PJM)

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Summary

• PSEG has already dramatically reduced its
  stationary source NOx emissions
• Water injection most viable technology for FT4
  peaking turbines
• Further unit-specific evaluation necessary

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Other Areas for Investigation

• Compensation with NOx allowances
• Restrict oil usage during ozone events
• Increase operating flexibility of clean units
• No stack testing when units not ordinarily
  running
• Airport NOx emissions (e.g. Newark)
• Electrification of truck stops
• Port Elizabeth, Port Newark
• Ferries

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Surrounding States

• PA
• Ozone season surrender NOx allowances for
  peaking turbines
• actuals greater than allowables
• CT
• same as PA
• NY
• Addressed in NOx RACT averaging plan
• DE
• Addressed in NOx RACT averaging plan