COMBUSTION COMPONENTS ASSOCIATES, INC.

884 Main Street, Monroe, Connecticut 06468

Tel: (203) 268-3139 Fax: (203) 261-7697
www.combustioncomponents.com

Pollution
Control
Retrofit
Keeps
Diesel
Generators
Operating­­­­February
,
2009

Selective
catalytic
reduction
(SCR)
technology
configured
with
a
diesel
oxidation
catalyst

(DOC)
combine
to
reduce
NOx
emissions
by
over
73%
and
CO
emissions
by
over
90%
on
diesel

generators
at
B.L.
England
Generation
Station
in
New
Jersey.




Combustion
Components

Associates,
Inc.

(CCA)

designed
and
installed
an

SCR
system
to
reduce
NOx

emissions
from
four
2,100

kW
diesel
generators
at
RC

Cape
May
Holdings’
B.L.

England
Generating

Station
in
Beesley’s
Point,

NJ.


The
NOx
reduction

system
was
done
as
a

“turnkey

project”
by
CCA
and
was
installed
and
commissioned
in
2007
to
comply
with
new

NOx
reduction
regulations
in
New
Jersey.



In
2008,
the
plant
was
required
to
reduce
CO
emissions
as
well,
and
CCA
re‐engineered
and

configured
the
internals
of
the
SCR
reactor
box
to
accept
a
diesel
oxidation
catalyst
(DOC).



B.L.
England
is
owned
by
RC
Cape
May
Holings,
LLC,
an
affiliate
of
Rockland
Capital
Energy

Investments,
LLC,
which
purchased
the
generating
station
including
the
4
diesel
engines
in

2007.
Rockland
has
made
significant
investments
to
improve
the
overall
environmental

signature
of
the
plant,
while
the
previous
owner
had
planned
to
shut
it
down.
These

investments
are
helping
B.L.
England
continue
as
an
important
source
of
local
power

generation
and
employment.





 2
A
novel
system
provides
game
changing
results

At
B.L.
England,
three
boilers
–
two
burning
coal
and
another
using
#6
fuel
oil–
provide

around
450
MW
of

power.
The
plant
is
located
on
the
Great
Egg
Harbor
Bay
in
New
Jersey.

The
4
X
2,100
kW
diesel
sets
provide
power
to
the
grid
during
peak
demand.
Prior
to

March
7,
2007,
New
Jersey
regulations
stipulated
that
lean‐burn
reciprocating
engines

fueled
by
liquid
fuels
and
capable
of
producing
an
output
of
500
bhp
or
more
were
subject

to
a
maximum
NOx
emission
rate
of
8.0
g/bhp‐hr.

Beginning
March
7,
2007,
liquid‐fueled

lean‐burn
stationary
engines
capable
of
producing
an
output
of
370
kW
or
more
were

subject
to
a
new
maximum
allowable
NOx
emission
rate
of
2.3
g/bhp‐h.






When
the
new
regulations
for
New
Jersey
went
into
effect,
the
prior
owner
decided
not
to

invest
in
new
pollution
control
equipment.
RC
Cape
May
Holdings,
the
new
owners,
decided

that
it
was
worthwhile
to
install
the
equipment,
and
selected
CCA’s

SCR
system.



The
CCA
SCR
Systems
are
a
popular
choice
for
exhaust
gas
NOx
reduction
on
diesel
engines,

lean
 burn
 natural
 gas
 engines,
 and
 boilers.
 In
 these
 systems,
 urea,
 a
 nonhazardous
 and

easy‐to‐handle
reagent,
is
metered
into
the
exhaust
gas
stream
just
upstream
of
a
catalyst.


Upon
injection
into
the
exhaust
gas
stream,
the
urea
decomposes
to
ammonia
which
reacts

with
NOx
compounds
forming
nitrogen,
water
vapor
and
carbon
dioxide.
The
major
system

components
are
a
reactor,
a
mixing
duct,
an
injection
control
module
and
urea
injectors.





At
 the
 heart
 of
 the
 CCA
 SCR
 system
 is
 a
 unique
 and
 proprietary

injection
system,
with
a
low‐cost,
single‐fluid
atomizer
(see
Figure
1)

designed
for
optimum
distribution
of
urea.
The
standardized
injector

is
self‐cooling
and
is
capable
of
operating
with
high
turndown.
One
of

the
unique
advantages
of
CCA’s
injector
design
is
that
it
is
capable
of

providing
 an
 optimum
 50‐60
 micron
 droplet
 size
 distribution,

without
an
atomizing
medium,
such
as
steam
or
compressed
air.








































































































Figure
1:

Non
air‐assisted
urea
injector

The
injector
ECU
is
programmed
to
control
the
urea
injection
rate
as
a
function
of
engine

parameters
related
to
NOx
emissions,
such
as
load
and
exhaust
gas
temperature.
It
can
also


Combustion Components Associates, Inc., 884 Main Street, Monroe, CT 06877 Ph: 203-268-3139 Fax: 203-261-7697
 3
be
operated
as
a
closed
loop
system
based
on
a
NOx
output
signal.
Injector
cycle
frequency

is
 factory
 set,
 and
 the
 period
 of
 time
 that
 the
 injector
 remains
 open
 is
 controlled
 by

modulating
 the
 signal
 to
 a
 solenoid
 actuated
 injector
 valve.
 These
 features
 significantly

reduce
the
lifecycle
cost
of
the
system.



Major
features
and
benefits
of
CCA’s
integrated
SCR
system
include:

• Proprietary
Injection
System
to
achieve
optimum
droplet
size
and
urea
distribution

in
the
exhaust
gas

• Optional
Closed
Loop
operation
for
NOx
trim
based
on
online
NOx
output
signal

• Airless
System
without
an
atomizing
medium
such
as
steam
or
compressed
air

• Programmable
Electronic
Control
of

urea
injection
rate
as
a
function
of
engine

parameters
through
a
laptop
computer
and
CCA’s
proprietary
software

• System
Optimization
and
performance
testing
using
portable
NOx
monitors
during

start‐up

• Carbon
Monoxide
(CO),
Hydrocarbons
(HC)
and
Particulate
Matter
(PM)
reductions

as
optional
design
features



Performance


The
combined
exhaust
train
flow
rate
for
each
of
the
four
2,100
kW
diesel
generators
is


approximately
25,694
ACFM
@
625°F.
The
CCA
system
reduced
NOx
emissions
from
a

baseline,
full‐load
level
of
8.4
g/bhp‐h
to
a
final
level
of
2.3
g/bhp‐h
‐‐
a
total
reduction
of

73%.

The
engines
had
three
separate
criteria
for
CO
compliance,
ppm,
lb/hr
and
g/bhp‐h,

which
were
not
consistent
.
In
order
to
meet
all
of
these
criteria,
R
C
Cape
May
Holdings

decided
to
install
Diesel
Oxidation
Catalysts.
CO
reductions
of
60%
‐
85%
using
DOCs
are

accepted
as
Generally
Applied
Control
Technology.


CCA
worked
with
the
owner’s
contractor
to
reconfigure
the
SCR
catalyst
to
allow
the

installation
of
the
DOC
catalyst
in
the
SCR
reactor
box.

CCA’s
DOC
add‐on
to
the
SCR
system

demonstrated
a
90+%
CO
reduction.

CO
emissions
were
reduced
from
a
full
load
baseline

level
of
500
ppm
to
a
final
level
of
<50
ppm.











Combustion Components Associates, Inc., 884 Main Street, Monroe, CT 06877 Ph: 203-268-3139 Fax: 203-261-7697
 4
Table
1
shows
NOx
and
CO
reductions
for
the
engine
exhaust
stream.

TABLE
1:

Diesel
Generator
Operating
Conditions
and
Emissions
Reduction
Using
CCA
SCR

and
DOC
System


Engine
Manufacturer
 General
Motors


Type
 EMD
2‐Stroke,
V‐16

Fuel
 ULSD

Generator
Output
 2,100
kW
each
(8,400
kW
total)

Exhaust
Flow
Rate
 25,694
ACFM
@
625°F

Exhaust
Maximum
Temperature
 825°F

Uncontrolled
NOx
corrected
to
15%
O2
 8.4
g/bhp‐hr
@
full
load

Final
NOx
 <2.3
g/bhp‐hr
@
full
load
(73%
reduction)

Uncontrolled
CO
corrected
to
15%
O2
 500
ppm

Final
CO
 <50
ppm
(>90%
reduction)





CCA’s
 innovative
 emission
 control
 solutions
 allow
 customers
 to
 meet
 stringent
 emission

control
regulations
in
a
cost‐effective
and
reliable
manner.
Our
products
and
solutions
are

backed
by
an
experienced,
U.S.‐based
engineering
field
service
and
technical
support
team.

Consulting
and
technical
services
available
from
CCA
include:



•
On‐site
Assessment

•
SCR
System
Engineering
&
Design


•
SCR
Catalyst
Selection

•
Installation
Review

•
DOC
Integration

•
Turnkey
Implementation

•
Commissioning
&
Start‐Up

•
Training
&
Procedures

•
Troubleshooting
&
System
Maintenance
 


Combustion Components Associates, Inc., 884 Main Street, Monroe, CT 06877 Ph: 203-268-3139 Fax: 203-261-7697