Rockwell Automation Air Pollution Control Solutions

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900D

Power GenerationAir Pollution Control Solutions

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Power Generation Trends

World Energy Demand continues to rise Environmental Regulations are forcing

changes Retrofits of Coal Plants Retiring Coal Plants New Natural Gas Plants – Shale Gas

Aging Plants and Infrastructure Retrofits Migrations

Renewables Increasing Renewable Portfolio Standards Tax Subsidies & Incentives Integration of Distributed Generation

Energy Independence & Security

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Environmental Regulations:USA - EPA Legislation & Impacts

U.S. Environmental Protection Agency’s (EPA) final Mercury and Air Toxics Standards (MATS) rule published on December 21, 2011 Plants must meet new standards by 2015 Retire plant Retrofit with new air pollution control

technology Cross-State Air Pollution Rule (CSAPR) finalized on

July 6, 2011 Requires states to significantly improve air

quality by reducing power plant emissions that contribute to ozone and/or fine particle pollution in other states.

Requires reduction of SO2 and NOX emissions from power plants in the eastern half of the United States. Source: U.S. Energy Information Administration Annual

Energy Outlook 2012 Early Release Overview

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Environmental Regulations:European Union - Directives

NEC – National Emissions Ceiling Directive Covers emissions in the territory of the Member States and their exclusive

economic zones from four pollutants which arise as a result of human activities: emissions of sulphur dioxide (SO2), emissions of nitrogen oxides (NOx), emissions of volatile organic compounds (VOC), and emissions of ammonia (NH3).

IED – Industrial Emissions Directive Successor of the IPPC Directive and in essence, it is about minimizing pollution

from various industrial sources throughout the European Union. IPPC Directive - integrated pollution prevention and control (until 2013)

LCP - Large Combustion Plant Directive Control of emissions from large combustion plants - those whose rated thermal

input is equal to or greater than 50 MW Sets ceilings and reduction targets for reducing emissions of acidifying pollutants,

particles, and ozone precursors.

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Environmental Regulations

Regulations will require air pollution controls to be deployed and/or updated at coal fired plants and industrial and campus sites with coal fired boilers. Flue Gas Desulfurization (FGD): SO2 removal Selective Catalytic Reduction (SCR): NOx removal Activated Carbon Injection: Mercury removal Coal plants without scrubbers account for a

majority of U.S. SO2 emissions

About 40% of coal-burning units don’t use add-on controls such as scrubbers.5


Power Producer Challenges

World Energy Demand requires Power Producers to: Maximize uptime Optimize generation from existing plants Drive innovation in new production capabilities

Government Regulations require Power Producers to: Reduce emissions Enhance security Increase the % of renewables in their portfolio

Controlling capital and operational costs to generate and deliver always available power safely and reliably

Sustainable power production

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Air Pollution Control Challenges

Adherence to global codes and standards Build once & deliver anywhere in the world

Desire to leverage latest technology & tools Utilities do not use state of the art technology in many cases

High availability and equipment reliability Improve operating efficiency

Application designed for Data Access More diagnostics and reporting Log data required for environmental reporting

Sustainable Production Reduce emissions & energy consumption Optimize use of raw materials used in the process (ammonia) Increase life of catalysts

Safe Operation Modular Solutions – including application code and equipment sub-assemblies Communication Protocols and Interlocking

Easily integrate equipment with DCS and other BOP equipment Support for various utility protocols

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Rockwell Solution Capabilities:Process Equipment to Power Plant Control

PlantPAx Solution Process Object Libraries speeds application development – AOIs

+Faceplates Advanced Process Control capabilities with Pavilion – process

optimization + regulatory compliance Integrated world-class Historian – OSIsoft Reporting – Views & Analytics based on user roles Alarms time stamped with high accuracy – Sequence of Event

Reporting with IEEE 1588 Endress + Hauser Partnership

Instrumentation Integration HART, Foundation Fieldbus, Profibus networks Asset Management – Instrument configuration & calibration

Integrated Architecture – a Single Platform Multi-disciplined Control for safety and process control in a single

platform Scalable Platform – OEM Skids to Power Plant Control Safety Shutdown Systems using GuardLogix

Modular Code templates makes deploying application quicker

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Rockwell Automation Value

PlantPAx solutions quickly & easily integrate into the Power Plant Control

Integrated Architecture System - Premier Integration of power, control, safety and networks

Product life cycle longevity of OTS components Networking capabilities meet your application demands

including: Time Synchronization (Sequence Of Events) Remote Diagnostics, monitoring and programming via EtherNet/IP Stratix EtherNet/IP Switch capability NERC-CIP / Cybersecurity

Solutions from our PartnerNetwork specialists Instrumentation – Endress & Hauser Solution Providers – EPC Firms and Systems Integrators Encompass Partners – Products/Components that enhance the platform

Global Support/Network of Technical Consultants

Rockwell Automation can help provide the total solution from standalone equipment to a completely integrated Power Plant Control system

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Proven Solutions and Technical Consultants

Modular Programming methodologies that follow industry standards

Leveraging PlantPAx libraries – process and power generation applications

Templates for quick code development while allowing creativity for equipment uniqueness

Technical Consultants can support in applying the correct solution

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Technical Consultants• Senior engineers with

extensive field experience• Focus: technical support

and cost reduction• Machine innovation• Best practice sharing• Training, examples, side by

side engineering, experience, knowledge


Proven Solutions using Process and Power Generation Libraries

PlantPAx Library Benefits Tested instructions which model real

devices Including simulation of devices for

operator training, strategy testing Consistent modes of operation

Avoid operator confusion Assist maintenance without having to

open logic Consistent interfaces between objects

Modular design eases construction of complex control strategies

Consistent user interface Standards-based HMI emphasizes

abnormal conditions Color palette tool to align HMI objects

with your color standards Reduced development and

maintenance time

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Power Generation Facilities Worldwide Deploy Nol-Tec’s Dry Sorbent Injection Systems

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Challenge• Meet tougher government regulations for SOx emissions

in coal fired power plants• Use the minimal amount of sorbent necessary to meet

the emission limits• Ensure chemical reaction occurs with the correct

amount of sorbent being injected• Develop scalable, standardized system with flexibility for

potential future modifications

Results• Diagnostics are readily available for faster

troubleshooting and preventative maintenance with the deployment of networked drives and MCCs

• Rockwell platforms provide flexibility to communicate directly with customer’s existing control system, for real-time data and control of sorbent injection loops

• “Plug and play” modules allow for system scalability with minimum system rework

Rockwell Automation’s Integrated Architecture allows for seamless integration of Nol-Tec’s DSI systems with power generation processing equipment, resulting in lower development costs and faster deployment.

Coal fired power generation facility improves emission mitigation of SO2 and SO3 by deploying a DSI system.


Korea Electric Power Corporation -FGD System

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Challenge• High maintenance costs due to outdated,

degraded system• Rapid installation to enable uninterrupted power• Environmentally systems part of the operations

that generate and deliver power• Utilize existing I/O system and field

instrumentation

Results• Uptime rate of 90%• Saved 30% in costs over implementing DCS

system• Met environmental goals• Reduced maintenanceEnvironmentally Friendly Power Solution Increases Utility

Uptime by more than 20%

Flue Gas Desulfurization Solution utilizing Rockwell Automation’s Integrated Architecture simplifies maintenance and improves operations.


European Power Stations using Alstom Power Solutions – FGD System

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Challenge• Use of COTS hardware and software to allow further

expansion using the same platform and modularity and to ensure a future migration path

• Produce standardized control system components for use across multiple Power Stations

• Meet power station requirements for control system standards

• Integration of new equipment with existing plant controls and operator interface

Results• Met environmental goals• Reduced maintenance• Easily transferable design allowed staff to move

from site to site for fast commissioning • Simulation model to test application sequences and

modes sped site commissioning• Modular code was deployed and reused across

multiple sites Wet flue gas desulfurization equipment reduces sulfur dioxide emissions by ~ 94%.

European coal fired plants are meeting the Large Combustion Plant Directive with Flue Gas Desulfurization equipment controlled with Rockwell Automation’s Integrated Architecture.


USA Utility’s Fleet of Power Plants deploy Activated Carbon Injection Systems

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Challenge• Fast track projects to comply with EPA regulations and

state sponsored mandates• Project schedule required precise timing to avoid penalties• Produce standardized control system components for use

across multiple power generation sites• Integration of new equipment with existing plant controls

and operator interface (DCS) – align DCS templates with stand-alone control functions

Results• Modular code was developed, deployed and reused across

multiple sites • Easy integration between BOP and Plant DCS by utilizing

Ethernet and a common data exchange format• Control system standardization results in improved

availability, spare parts, and operational training• Improved maintenance – Plant DCS operation as well as

local operator interface at the equipment provided the diagnostics required for faster troubleshooting

Rockwell Automation’s Integrated Architecture deployed on the ACI subsystem provides full standalone process control in addition to integrating into the existing DCS infrastructure.

As part of the utility’s environmental improvement program for their fleet of 800 MW and higher generation plants, the utility added activated carbon injection systems.


Arkansas Electric Cooperative Corporation (AECC) – Software CEM®

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Challenge• Must meet stringent regulatory standards for

environmental quality• Hardware emission monitor equipment obsolete

and needed to be replaced • Reduce maintenance labor, eliminate

consumables, reduce cost of operation

Results• Cost Savings: One year ROI over a CEMS

hardware replacement investment • Reduced need for skilled maintenance

labor • Reduced consumable costs associated with

calibration gases • Reduced energy consumption • System Certified Through a Relative Accuracy

Test Audit (RATA)• Certified at < 7.5% for less then 10ppm NOx

Software CEM® is helping AECC save more than $50,000 per year in costs relative to operating a hardware-based CEM system.

AECC Benefits from Sustainable Emissions Monitoring, Reduced Operating Costs and Greater Accuracy through Software CEM® from Rockwell Automation.


Typical Architectures & Solutions

Coal Fired Power Plant Pollution Control Equipment Including SCR Optimization Model

Gas Fired Power Plant Pollution Control Equipment Including Software CEM® & SCR Optimization Models

Medium Voltage Drives for ID & FD Fans

Condition Based Monitoring Systems

Software CEM® - Continuous Emission Monitoring System (CEMS)

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Coal Fired PlantPollution Control Equipment

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Gas Fired PlantPollution Control Equipment

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Sample Architecture –an Advanced Technology Approach

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Rockwell Solution Capabilities:Medium Voltage ID / FD Fan Applications

PowerFlex 7000 Direct to Drive Technology Eliminates the Isolation Transformer - increases the efficiency of the whole

string Allows any motor brand to be selected by the pump manufacturer

Integrates easily with PlantPAx or 3rd Party DCS solutions Networking Options -Profibus DP, Modbus TCP, EtherNet/IP, etc.

Robust and Safe Design More than 16 years MTBF for the whole Drive Symmetrical Gate Commutated Thyristor (SGCT) - Non-rupture, non-arc

failure mode Lower Mean Time To Repair (MTTR) reduces lost production costs

Simple, reliable power structure with low component count Fewer devices / simpler design minimizes maintenance requirements Easy to maintain – SGCT can be changed quickly without special tools

Standards Meets IEEE 519-1992 Harmonic Guidelines Certified equipment for 50ºC operation (all the elements including DC Power

Supply, Control system, etc.)

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Typical Fan/Pump Monitoring & Protection System Architecture

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Rockwell Solution Capabilities:Condition Based Monitoring Systems

BOP Fans & Pump Skids - Condition Based Monitoring Solution Scalable options – walk around to fully integrated

solutions Integrates easily to PlantPAx or 3rd party DCS solutions

Real-time Protection Protection from catastrophic failures - Alarms can be

linked to equipment relays to shutdown equipment on dangerous levels of vibration

Predictive Maintenance Predictive maintenance package is needed to flag

pending pump problems before they occur Better scheduling of Preventative Maintenance

Diagnostics Knowledge of the root cause of the equipment failures

(unbalance, looseness, misalignment, or bad bearings) Reduced downtime, spare parts and emergency repair costs

Prevent this from happening

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The Software CEM® Solution

An Emission Model is developed and then run in real-time. The model reflects the relationship between process operations and ambient conditions to emissions.

A Patented Sensor Validation is utilized to ensure the accuracy of the predicted emissions data.

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Rockwell Solution CapabilitiesSoftware CEM®

Cost Effective Monitoring & Compliance A proven, model-based, software solution that leverages existing process

instrumentation and data Does not require additional capital equipment or real estate Up to 50% less cost to install and maintain than hardware CEMS

No specially trained technicians/dangerous environments/hazardous materials No consumable products, thus no increase in material operating costs

Highly Accurate & Reliable Emissions Monitoring & Reporting Continuous, real time sensor validation & emission performance

Detects & alerts operator to sensor failures Meets strict continuous emissions monitoring data availability requirements of

95% or more Accurate emissions modeling with robust prediction capabilities 100% data validation lowers the risk of inaccurate reporting

Environmental and Industry Experience & Expertise Proven solutions that meet unique, local regulatory requirements Meets all US EPA requirements for PEMS

40 CFR Part75; Subpart E for “Alternative Monitoring Systems” 40 CFR Part 60; Appendix A, Performance Specification 16 (PS-16)

100% Certification Record with 300+ PEMS installations

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Rev 5058-CO900D

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