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2010 Gas-Electric Partnership
Emissions Reduction from Legacy Engines
February 11, 2010Houston, TX
Bill Couch, El PasoMike Whelan, PRCI
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Emissions Reduction from Legacy Engines (ERLE) R&D Program
An ongoing, multi-year effort to minimize the impact of retrofitting pipeline reciprocating engines to meet increasingly stringent air quality regulations
Program started in 2004, anticipating that the EPA trajectory for Ozone regulations would create a significant financial exposure for many pipelines Needed to reduce the cost of retrofit NOx options, ensure their
wide applicability and ensure no performance compromises
This presentation will review the technical status of the ERLE program, and how its original drivers have evolved.
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Pipeline Research Council Int’l. Overview
MembershipPipelines – 36, over 350,000 miles of pipe
• 26 with significant North American assets• 5 are Liquids-only (plus trade association – AOPL)• 9 are major integrated companies with both gas and liquids
Associate Members – 15• General Electric, Solar Turbines, Cameron, Dresser-Rand• Numerous linepipe manufacturers and ILI vendors
FundingAnnual subscription – formula based on pipeline mileage
• 2009 R&D program size: $7,287K
4PRCI’S Mission
“To conduct a collaboratively funded research program that enables energy pipeline companies around the world to provide safe, reliable, environmentally compatible, and cost effective service to meet customer energy requirements. ”
Drivers of PRCI’s members Total Asset Management for Reliability, Integrity, and Productivity Controlling Operational Risk Near-term Expansion to Accommodate New Fuels and Markets Enhancing Public and Regulator Awareness and Acceptance Environmental Performance System Flexibility The Loss of the Knowledge and Skill Base
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Research Allocation & Committees - 2010
Pipeline Program (~73% of funding, $5.3MM )CorrosionDesign, Materials and ConstructionOperations & Integrity41 Projects total
Facilities Program (~27% of funding, $2.0MM)Compressor & Pump Station ($1.178 MM)MeasurementUnderground Storage23 Projects total
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Compressor & Pump Station Projects
Legacy Engine Emissions Reduction
Gas Turbine O&M issues
Compressor & Pump Station facility integrity
Greenhouse Gas monitoring and reporting protocols
Liquid Pump efficiency improvements
Ozone Nonattainment: 1-hour Ozone NAAQS – 1990
Initial focus on “urban” areas within highlighted regions-“Ozone Transport Region”created (New England & NY, NJ, PA, MD)
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**The Fine Print
From the footnote on the prior 2020 slide Modeled Emissions in 2020 include the effects by 2020 of
various Federal programs including:-Clean Air Interstate Rule-Clean Air Mercury Rule-Clean Air Visibility (particulates) Rule-Clean Air Non-Road Diesel Rule-The Light-Duty Vehicle Tier 2 Rule-The Heavy-Duty Vehicle Rule…..and a couple of other programs.
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Cost Exposure
NOx ControlScenario
Engines Affected
(estimated)Probability that High-level NOx
Controls will be required Cost
Exposure
-Units located within existing ozone non-attainment areas with a unit size >3,000 hp
420(1.76 MM
hp)
Almost certainto occur
$2.2 billion(Replacement cost of
$1,250/hp)
-Units located within existing ozone non-attainment area with emissions > 1 ton per day-Units located near/within a non-attainment area with unit emission >100 tons per year
1,000(2.5 MM
hp)Very likely
$3.125 billion(Replacement cost of
$1,250/hp)
Expand NOx SIP requirements beyond Eastern states per the CAIR rule for all units >1,000 hp
2,500(4.4 MM
hp)
NOx SIP area expansion very likely, unit control needs determined state
by state
$5.975 billion (Replacement cost of
$1,250/hp for large units, $1,500/hp for
smaller units)
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Non-SIP Drivers for NOx Controls
Facility expansions or increases in engine utilization that trigger Prevention of Significant Deterioration reviews and corresponding implementation of BACTand/or NOx offsets
Unit maintenance, reconstruction or debottlenecking that triggers New Source Review and potential requirement for BACT emissions levels.
The periodic need to over-control engines as a display of good faith to expedite permit approvals or to resolve a prior compliance issue
Some states implement stringent permitting and retrofit programs simply as a matter of policy and desired eco-profile.
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NOx Considerations
Pressure to reduce Ozone continues & eventually States will run out of other NOx tons to controlMost powerplants will have SCR controls Automobiles are already very clean Pipelines often the second or third largest source category in many
states - they won’t go unnoticed Other NOx drivers – Regional Haze & Particulates New high-speeds can achieve ½ gram NOx Electric motor equivalency is below ½ gram Some states continue to push SCR (80% control of 3g) NO2 Rules just established – 2020 compliance Bottom line – need a toolkit to achieve ½ gram
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Specific ERLE Program Objectives
The overall ERLE objective is to develop technical options that allow: NOx emissions as low as 0.5 gm/hp-hrNo increase in other emissions or fuel consumptionNo decrease in operating range or reliabilityOperation across the full span of ambient conditionsCosts ranging from 1/6 to 1/3 of engine replacement costs Implementation on 80% of the legacy engine population
Engine control strategies and optimized components developed can also be used to maximize fuel efficiency.Thus, significant fuel reductions and associated GHG
reduction opportunities are inherent to this program.
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ERLE Planning
A perpetual challenge to R&D is avoiding disconnects between research and commercialization
We sought to head-off this predicament by involving stakeholders in the Roadmap process early and often Sponsor: PRCI (through its member companies) Primary Research Contractors:
• Advanced Engine Technologies, Inc.• Colorado State University• Kansas State University• Innovative Environmental Solutions
Vendors (providing commercialization channels and cost-share): Hoerbiger, Cameron, D-R Enginuity, Exterran, Kistler
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Specific Program Objectives
The overall ERLE objective is to develop technical options that allow: NOx emissions as low as 0.5 gm/hp-hr No increase in other emissions or fuel consumption No decrease in operating range or reliabilityOperation across the full span of ambient conditions Costs ranging from 1/6 to 1/3 of engine replacement costs Implementation on 80% of the legacy engine population
An additional value is that engine control strategies and optimized components can maximize fuel efficiencyThus, fuel reductions and associated GHG reduction
opportunities are inherent to this program
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Specific Technical Elements
A thorough assessment of the factors that could enable ultra-low NOx operation identified six discrete technical dimensions that govern overall engine performance and emissions:
1. Engine closed-loop controls, including engine sensors
2. Emissions aftertreatment3. In-cylinder fuel and air mixing4. Air delivery (at the turbocharger and engine
frame level)5. Air management (at the cylinder level)6. Ignition systems
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Review Criteria for each Dimension
Provide Technology DescriptionCharacterize State-of-the-Art Identify Technology Gaps ID Areas of Promising Technology
DevelopmentConsider technologies from other sectors:AutomotivePower Generation
Establish Status of Progress of each Technology Dimension along the Roadmap
The ½ Gram Engine – Emission/Technology Map
NOx Level
Req
uire
d U
pgra
de
0.5 g/bhp-hr 1 g/bhp-hr 3 g/bhp-hr 5 g/bhp-hr 10 g/bhp-hr
OEM Reduced Load, Retarded Ignition
Turbocharger Upgrade (“More Air”)
High Pressure Electronic Fuel Injection (EFI)
Prechamber (PCC)
closed loop ePCC
Advanced TER Control
Transient Control
A/F Control
Balancing & Diagnostics
Advanced Ignition System
ePCC
Alternative Approach
We can get there from here – at reasonable cost
The ½ Gram Engine – Emission/Technology Map
NOx Level
Req
uire
d U
pgra
de
0.5 g/bhp-hr 1 g/bhp-hr 3 g/bhp-hr 5 g/bhp-hr 10 g/bhp-hr
OEM Reduced Load, Retarded Ignition
Turbocharger Upgrade (“More Air”)
High Pressure Electronic Fuel Injection (EFI)
Prechamber (PCC)
Transient Control
Advanced TER ControlA/F Control
Balancing & Diagnostics
Advanced Ignition System
closed loop ePCCePCC
Alternative Approach
The foundation of all NOx reduction projects is aturbo re-aero ($$) or turbo replacement ($$$$)
Progress within ERLE Technical Dimensions
Commercialization of Turbocharger Monitoring System “TurboShield” by Exterran
SAS 1b.2 predictive controller 1b.3 predictive controller 1b.4 predictive controllerAS 1c. Cyl/Cycle controller 1c.2 Cyl/Cycle controller 1c.3 Cyl/Cycle controller 1c.4 Cyl/Cycle controllerA
SASAS 2c. NSCR - controls 2c.2 NSCR - controlsASA
S 3a. Active Air Control 3a.2 Active Air ControlA
S 4a. HCCIA
S 5a. Turbo Peaking 5a.2 Turbo Peaking 5a.3 Turbo PeakingAS 5b. Turbo Comp. MatchAS 5c. Turbo Monitoring 5c.2 Turbo MonitoringA
SA
Technology Performance Information or Specification
Analysis/ Design/ Fabrication Commercial Product Available
Prototype Demonstration
Field Evaluation On-Ramp Off-Ramp
Field Demonstration (pre-prod.)
2010TECHNOLOGY
DIMENSION2009
2. Aftertreatment Controls
Identifying a commercialization partner prior to further work.
1a. cylinder-level sensors 1a.2 cylinder-level sensors
Sche
dule
d/
Act
ual
1. Closed-Loop Controls
SCR performance on pipeline engines
2a.2 SCR slip-stream 2a.3 SCR full-scale
6a.3 PCC multi-cylinder
1b. Predictive controller
2006 2007 2008
6a. PCC 1-cylinder 6a.1 PCC 1-cylinder
No Projects Planned
2a. SCR slip-stream
6a.4 PCC multi-cylinder
2b. Oxicat State-of-ArtCANCEL
2c. NSCR - controls
2d. NSCR State-of-ArtDefer to 2008
Delay start to 2007
3a.4 Active Air Control 3a.5 Active Air Control
2d. NSCR State-of-Art
6. Ignition
4. Combustion 3. Air
6a.2 PCC multi-cylinder
3a.3 Active Air Control
5. Air Delivery 5b. Turbo comp. match?
Participation and cofunding from two potential commercial partners
Comments
Expected to become Hoerbiger product.Expected to become Hoerbiger product. May be combined with 1b.
HCCI has taken the off-ramp (will not be pursued)
Oxidation catalyst work is mature and will not be pursured (off-ramp)
Altronic/Hoerbiger product. '07 work pending site selection & test
performance and by-product emissions
Identifying a commercialization partner prior to further work.
On-hold pending vendor cofunding
YOU ARE HERE
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Mid-Course Corrections
Inherent to the strategy for a Dimension was the expectation of program “on-ramps” and “off-ramps” Certain technologies would be down-selected Alternative approaches would be initiated
Some technologies evaluated have significant barriers e.g., homogeneous charge compression ignition (HCCI) Pre-combustion chambers after OEM offerings emerged New understandings were gained and documented in project reports
Other technologies, such as oxidation catalysts, were reviewed and considered to be adequate However, the future large engine lean-burn MACT revisions were not
anticipated – so we are characterizing oxycat technology vs. formaldehyde in 2010 & 2011.
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Industry Oversight
5-year research program comprised of 6 technology dimensions and multiple projects per dimension quickly becomes a project management challenge
An oversight team, consisting of “20 Percenters” from PRCI member companies, was established for each of the 6 dimensions
While each project has a milestone schedule (Gantt chart) prepared and maintained by the research contractor, an overall program milestone chart was created to show deliverables, overall progress and project cross-relationships
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Progress within ERLE Technical Dimensions
System Integration (organizing the tools in the toolbox)
Trade-off studies were identified potential application configurations for the variety of ERLE technologies
There are many opportunities to layer equipment, depending on the extent of NOx reductions needed, and the nature of the engine
This was used to identify remaining development needs, and to plan the 2010 ERLE integrated engine test configuration
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Integrated Engine Test
Clark TCVA-10 at Southern Natural – Gallion, AL Hoerbiger Hyperfuel (High Pressure Engine Fueling) Hyperbalance II and III. (Cylinder auto-balance using Kistler sensors
as the in-cylinder sensor and feedback loop)• Pressure-ratio balance
Electronic Precombustion Chambers with ion sense in PCC Present configuration: MAN 48 turbocharger (has excess capacity)
and Bristol controller Current permit of 2.2 grams NOx, 2.7 grams CO, 1.5 grams VOC
Site test objectives Improved margin of compliance on NOx/CO trade-off Demonstrate lowest possible NOx – to ½ gram NOx ideally. Demonstrate ability to operate at 60 to 120% torque on hot day. ID benefits of reduced misfires and reduced damage factor
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Integrated Engine Test
Clark TCVC-20 at ANR Pipeline – Eunice, AL Hoerbiger Hyperfuel (High Pressure Cylinder Fueling) Hoerbiger Hyperbalance II & III Electronic PCC’s with ion sense New turbocharger NOx 2.7 grams, CO 2.8 grams
Main site objective is to expand operating range to very low loads while maintaining compliance Demonstrate range of 30% to 120% torque Test as layers of technology – before and after new turbo
installed. Determine incremental NOx reductions ID benefits of combustion stability, damage factor monitoring
and fuel rate Potentially install TUBS to assist with cold starts
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