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OPPD engaged Primex to improve scrubber reagent quality and production capacity. Results included a 25% increase in reagent quality, 29% increase in reagent production capacity and 95% decrease in atomizer scale formation.

OPPD engaged Primex to improve reagent quality and production capacity, including historical process data analysis, chemical analysis, reagent preparation system modeling, simulation, and testing. Key factors were identified and recommendations implemented including specific actions to select the source, treatment, and temperature of water used for lime slaking and dilution in the DFGD process.

Success of the analytical services program at NC2 depended on clear goals and close collaboration between OPPD and Primex personnel. Other critical factors included a comprehensive understanding of best-practice standards, access to plant data, plus advanced diagnostics with quantitative modeling and simulation techniques.

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SITUATION

Omaha Public Power District operates two generating units at their Nebraska City Station near Nebraska City, NE. Nebraska City Unit 2 (NC2) is a 682 MW coal-fired facility equipped with a dry flue gas desulfurization (DFGD) system including onsite reagent preparation equipment, spray dry absorbers and rotary atomizers. A comparison of NC2 with similar facilities showed reagent consumption was 30-50% higher than average with related challenges in reagent preparation capacity and material handling. Rapid scale formation in reagent atomizing equipment compromised reliability and required excessive maintenance resources to control.

SOLUTION

OPPD engaged Primex to identify opportunities that would improve reagent quality, increase reagent production capacity and control scale formation at NC2. The scope of work included historical process data analysis, chemical analysis, reagent preparation system modeling, simulation and testing. This information was compiled and further analyzed to identify key factors affecting reagent quality, production capacity and scale formation. The resulting recommendations were implemented at the plant, after which ongoing analytical services provided by Primex continue to track performance and results.

RESULTS

The analysis by Primex revealed substantial opportunities to improve reagent quality, increase reagent production capacity, and control scale formation. Recommendations included specific actions to select the source, treatment, and temperature of water used for lime slaking and dilution in the DFGD process. After implementation, the following results were achieved:

  • Reagent quality (as measured by lime slurry reactivity) increased by 25%
  • Reagent production capacity (as measured by slaking rate) increased by 29%
  • Scale formation in atomizers decreased by 95%

CRITICAL SUCCESS FACTORS

Success of the analytical services program at NC2 depended on clear goals and close collaboration between OPPD and Primex personnel. Other critical factors included a comprehensive understanding of best-practice standards, access to plant data, advanced diagnostics with quantitative modeling and simulation techniques.