Renovo Energy Center Plan Approval Application

407 Pages·2015·22.43 MB·English

by  Colby Sturtevant

August 5, 2015

RENOVO ENERGY CENTER, LLC

Plan Approval Application
Renovo, Clinton County, Pennsylvania

PROJECT NUMBER:
137575

PROJECT CONTACTS:
Tim Donnelly
EMAIL:
[email protected]
PHONE:
[phone]

Amy Austin
EMAIL:
[email protected]
PHONE:
[phone]

Tom Rolfson
EMAIL:
[email protected]
PHONE:
[phone]
POWER ENGINEERS, INC.
303 U.S. ROUTE ONE
FREEPORT, ME 04032 USA

PHONE [phone]
FAX [phone]

August 5, 2015

Mr. Muhammad Zaman
Regional Air Quality Program Manager
PA DEP Northcentral Regional Office
208 W. Third Street, Suite 101
Williamsport, PA 17701-6448

Subject: Renovo Energy Center, LLC Plan Approval Application

Dear Muhammad:

On behalf of Renovo Energy Center, LLC, POWER Engineers, Inc. is submitting three copies of a
Plan Approval Application for the proposed Renovo Energy Center, LLC dual fuel fired
combined-cycle electric generating plant in Renovo, Clinton County, Pennsylvania. We appreciate
you meeting with us to review the application.

The application consists of the following sections with supporting attachments:

Section 1: Project Overview
Section 2: Applicable Requirements
Section 3: Control Technology Analyses
Section 4: Ambient Air Quality Analyses
Section 5: PaDEP Plan Approval Application Forms
Section 6: Non-attainment Area Requirements

As you are aware, the facility is collecting on-site meteorological data for the ambient air quality
analyses which will be submitted in the fall of 2016.

Also enclosed is a check in the amount of $29,700 made payable to the Pennsylvania Clean Air
Fund for the required application fee.

If you have any questions, please contact me at 207-869-1282.

Sincerely,

Tim Donnelly
Senior Project Manager

Enclosure(s):
c: Rick Franzese, Bechtel Development Company
DMS 137575/PER-02-02-09

FRE 164-303 137575 (08/05/2015) CD

Renovo Energy Center, LLC
Plan Approval Application Index

Section 1: Project Overview
Section 2: Applicable Requirements
Section 3: Control Technology Analyses
Section 4: Ambient Air Quality Analyses
Section 5: Pennsylvania DEP Plan Approval Application Forms
Section 6: Non-Attainment Area Requirements

Attachment A: Site Location on USGS Map
Attachment B: REC Project Site Plan
Attachment C: Emission Calculations
Attachment D: Vendor Data
Attachment E: BACT/LAER Clearinghouse Determinations Summaries
Attachment F: Process Flow Diagrams
Attachment G: SCR PID
Attachment H: Cost Analysis Information (SCR for Turbines and OxCat for Auxiliary Boilers)
Attachment I: Storage Tank Information
Attachment J: Municipal Notifications
Attachment K: Registry of Available NOx and VOC offsets
Attachment L: Meteorological Monitoring Plan and DEP Approval Letter
Attachment M: PHMC Project Review Information

FRE 164-304 (PER-02-02-09) REC (08/05/2015) 137575 CD PAGE i
Section 1
Section 1
Project Overview
Table of Contents

1.1 Project Description ........................................................................................................................ 1
1.2 Site Location ................................................................................................................................. 1
1.3 Process/Equipment Description .................................................................................................... 1
1.3.1 Combustion Turbine Generators ........................................................................................... 2
1.3.2 Turbine Inlet Evaporative Coolers ........................................................................................ 4
1.3.3 Heat Recovery Steam Generators with Duct Burners ........................................................... 4
1.3.4 Steam Turbine Generator ...................................................................................................... 4
1.3.5 Auxiliary Boilers .................................................................................................................. 4
1.3.6 Fuel Gas Heater .................................................................................................................... 5
1.3.7 Diesel-Fired Emergency Generators ..................................................................................... 5
1.3.8 Diesel-Fired Emergency Fire Water Pump ........................................................................... 5
1.3.9 Fuel Oil Storage Tanks ......................................................................................................... 5
1.3.10 Aqueous Ammonia Storage Tank ........................................................................................ 5
1.3.11 Lube Oil Storage Tanks ........................................................................................................ 5
1.3.12 Circuit Breakers .................................................................................................................... 5
1.4 Project Schedule ............................................................................................................................ 6
1.5 Facility Emissions Calculations .................................................................................................... 6
1.5.1 Combustion Turbines/HRSGs ............................................................................................... 6
1.5.2 Auxiliary Boilers and Fuel Gas Heater ................................................................................. 8
1.5.3 Emergency Generators and Fire Pump ................................................................................. 9
1.5.4 Facility Wide ....................................................................................................................... 10

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POWER ENGINEERS, INC.
Project Overview for Renovo Energy Center, Renovo, PA

1.1 Project Description

Renovo Energy Center, LLC (REC) proposes to construct a nominally rated 950 MW (net) dual fuel
(natural gas and ultra-low sulfur diesel (ULSD)) combined cycle electric generating plant in Renovo,
Pennsylvania The proposed REC facility will consist of two 1-on-1 power blocks consisting of a
combustion turbine and a steam turbine in line to produce electricity for distribution into the transmission
grid system. Each combined cycle system consists of a Combustion Turbine (CT), which is intended to
be fired on natural gas unless there is an interruption in supply, and a Heat Recovery Steam Generator
(HRSG). The steam from the HRSGs is routed through the condensing steam turbine generator. With the
exception of the General Electric option, each HRSG has a gas fired Duct Burner (DB) for supplemental
firing. REC will utilize air cooled condensers for condensing the exhaust steam, which is an
environmentally preferred method as compared to a traditional wet cooling tower.

REC is requesting a plan approval that will allow three optional plant configurations, each having a
different original equipment manufacturer (OEM). The three OEM configuration options being
considered are the General Electric (GE) 7HA.02, Siemens SGT6-8000H, and Mitsubishi Hitachi Power
Systems America, Inc. (MHPSA) M501J units. Due to pricing, performance, design considerations, and
delivery schedule, a final decision on the preferred OEM will be made after a plan approval has been
issued, thus the application is structured to reflect the three different options. REC will submit a written
request to Pennsylvania Department of Environmental Protection (PaDEP) to withdraw two of the three
two options prior to the start of construction.

The proposed REC facility will also include two auxiliary boilers, two emergency generators, an
emergency firewater pump, and a natural gas heater. The HRSG DBs, the auxiliary boilers, and fuel gas
heater will only combust pipeline quality natural gas. The emergency firewater pump and emergency
generator will utilize ultra-low sulfur diesel fuel oil.

In addition to the aforementioned combustion devices, the REC facility will also have potential air
emissions from the petroleum storage tanks, ammonia slip from selective catalytic reaction process, and
SF6 containing circuit breakers.

1.2 Site Location

REC’s proposed site is a 68-acre parcel located north-northeast of the Town of Renovo between Erie
Avenue and Industrial Park Road. The site is the location of the former PRR/Philadelphia & Erie
railroad car renovation facility.

The approximate UTM coordinates of the proposed site are 269.4455 kilometers (km) Easting and
4578.8724 km Northing. The project will be located at a base elevation of approximately 670 feet above
mean sea level. The immediate project site consists of flat terrain in an east-west orientated river valley
with increasing elevated terrain to the north and south of the proposed site.

1.3 Process/Equipment Description

Attachment A includes a site plan with the proposed location of the buildings and equipment indicated.
REC is proposing to install and operate the following devices:

• Two GE 7HA.02 (each @ ~3,558 MMBtu/hr, High Heating Value (HHV)), or Siemens SGT6-
8000H (each @ ~3,124 MMBtu/hr, HHV), or MHPSA M501J (each @ ~3,301 MMBtu/hr,
HHV), natural gas/ULSD fired combustion turbines with inlet evaporative coolers;
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POWER ENGINEERS, INC.
Project Overview for Renovo Energy Center, Renovo, PA

• Paired with each combustion turbine, one condensing steam turbine and one driven electric
generator;
• Two heat recovery steam generators (HRSG) with supplementary natural gas-fired duct
burners (no duct firing with GE option), each rated at 695 MMBtu/hr (HHV) heat input for
the Siemens SGT6-8000H and 435 MMBtu/hr (HHV) heat input for the MHPSA M501J;
• Two natural gas-fired auxiliary boilers (one for each power block), each rated at 30
MMBtu/hr heat input;
• Two diesel-fired Emergency Generators, (one for each power block) rated at 750 kW
(~8.4 MMBtu/hr heat input);
• One natural gas-fired fuel gas heater, rated at 18 MMBtu/hr heat input;
• One diesel-fired Emergency Fire Water Pump, rated at 250 hp (~1.8 MMBtu/hr heat input);
• Two Aqueous Ammonia aboveground storage tanks with a capacity of 15,000 gallons each;
• Ultra-low sulfur diesel oil aboveground storage tank with a capacity of 3.8 million gallons;
• Two lube oil aboveground storage tanks each with a capacity of 20,000 gallons; and
• Eight high voltage circuit breakers containing sulfur hexafluoride within the facility’s electrical
switchyard.
1.3.1 Combustion Turbine Generators

Each combustion turbine power block will include an advanced firing combustion turbine, air
compressor section, gas combustion system (utilizing dry, low-NOx combustors), power steam turbine,
and a generator.

The combustion turbine is the main component of a combined-cycle power system. First, air is filtered,
cooled by the evaporative cooler during warm weather, and compressed in a multiple stage axial flow
compressor. Compressed air and fuel are mixed and combusted in the turbine combustion chamber.
Lean pre-mix dry low-NOx combustors minimize Nitrogen Oxide (NOx) formation during natural gas
combustion. When combusting oil, water injection will be employed to reduce thermal NOx formation.
Hot exhaust gases from the combustion chamber are expanded through a multi-stage power steam
turbine that results in energy to drive both the air compressor and electric generator.

In combined-cycle mode, the exhaust gas exiting the power turbine is ducted to a boiler commonly
known as a heat recovery steam generator, or HRSG, where steam is produced to generate additional
electricity in a steam turbine generator. With the exception of GE’s power block, which does not require
duct firing, natural gas- fired duct burners located within the HRSGs are used for supplementary firing
to increase steam and electrical output.

REC’s combustion turbines will be designed to operate in the dry low-NOx mode at loads from
approximately 60 percent up to 100 percent rating.

REC’s combustion turbines will operate at very low NOx levels when operating in steady state conditions
through the use of low NOx combustors, proper operation, and selective catalytic reduction (SCR)
technology. During periods of startup and shutdown (SUSD) the emissions from the combustion turbines
are not controlled to the levels of steady state operation due to flue gas and catalyst temperatures not
being high enough to effectively operate the SCR. Independent of the turbine manufacturer or model
number, SUSD NOx emissions will be significantly higher than steady state load conditions. The higher,
uncontrolled NOx emissions during SUSD cannot be avoided.
SUSD periods allow for thermal stabilization of the combined cycle power train to allow for efficient and
recommended operation.
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Project Overview for Renovo Energy Center, Renovo, PA

A combined-cycle turbine power train generates power from the combustion turbine while simultaneously
recovering and transferring high temperature exhaust energy to the steam turbine to increase power
production and overall unit efficiency. The benefits of employing combined cycle technology/design is
the relatively short SUSD time and ability to quickly change loads as compared to boiler systems used for
generating electricity, and the significantly higher generating efficiency as compared to a gas turbine in
simple cycle mode.
Combined-cycle units have different startup times depending upon the amount of time since the unit was
last operated, which are typically referred to as either hot, warm, or cold startups. The specific startup
time will vary based on turbine manufacturer, model, and ambient conditions. In general and for the
purposes of this application, the following summarizes startup periods:
• Hot Start = unit has not operated in 8 hours or less;
• Warm Start = unit has not operated in between 8 to 72 hours;
• Cold Start = unit has not operated in over 72 hours.

There are three main stages of a combined cycle startup: purging of the HRSG; gas turbine speed up,
synchronization, and loading; and steam turbine speed up, synchronization, and loading. At
approximately 60% combustion turbine load suitable steam properties for the steam turbine startup are
reached. As stated previously, the startup time for the CT, HRSG and steam turbine are dependent on how
long the unit has been out of operation prior to startup. To avoid thermal stress, various components of
the steam turbine must be brought up to temperature prior to normal steam turbine operation. In a
combined cycle system, the amount of time since previous operation of the steam turbine and HRSG
factors into the temperature of components and dictates how long the startup period will be.
Startup is defined as from GT initial fire to HRSG stack emissions compliance. Shutdown is from the
time HRSG stack goes out of compliance during shutdown to termination of fuel flow. The following
describe SUSD times in ideal conditions for each manufacturer and type of startup; actual startup
/shutdown times will be longer, which is reflected in our permit request.
For GE units on natural gas, a hot start is 20 minutes in duration, warm 40 minutes, and cold 45 minutes
with shutdown 14 minutes. For Siemens units on natural gas, a hot start is 30 minutes in duration, warm
35 minutes, and cold 35 minutes with shutdown 18 minutes. For MHPSA units on natural gas, a hot start
is 28 minutes, warm is 103 minutes, and cold is 143 minutes while shutdown is 13 minutes.
For GE units on ULSD, a hot start is 20 minutes in duration, warm 40 minutes, and cold 45 minutes with
shutdown 8 minutes. For Siemens units on ULSD, a hot start is 32 minutes in duration, warm 35 minutes,
and cold 35 minutes with shutdown 18 minutes. For MHPSA units on ULSD, a hot start is 37 minutes,
warm is 125 minutes, and cold is 182 minutes while shutdown is 14 minutes.
Typically, upon reaching a load greater than 60% capacity with the HRSG/SCR temperature of
approximately 570°F the startup period is considered complete as the pollution control equipment can
now effectively operate. At this point (steady state load), NOx emissions can be met.
During the shutdown of a combined-cycle unit the combustion turbine load is significantly reduced (in
general and for the purposes of this application, shutdown period is when the combustion turbine operates
at or below 50% load). Once the combustion turbine’s exhaust gas temperature is below a manufacturer’s
specified minimum, the steam turbine is then shut down. The combustion turbine load is further reduced
until the unit is shut off.
The combustion turbines/HRSG will also contain an oxidation catalyst system for reducing exhaust gas
emissions of Carbon Monoxide (CO) and Volatile Organic Compounds (VOCs). The catalyst promotes
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POWER ENGINEERS, INC.
Project Overview for Renovo Energy Center, Renovo, PA

the oxidation of CO and VOCs compounds to carbon dioxide and water as the exhaust gas passes
through the oxidation catalyst bed. There are no reactants used in the catalyst system, the oxidation to
CO and water spontaneously occurs.
2

1.3.2 Turbine Inlet Evaporative Coolers

During hot and humid ambient air conditions, REC will employ evaporative cooling to cool the air
entering the combustion turbine (CT) by evaporating water sprayed into the air intake, immediately
following the inlet filter. A mist eliminator will prevent water droplets from reaching the turbine blades.
The cooling of the inlet air increases the density of the air entering the CT resulting in increased output
capacity. CTs are volumetric processes that produce more power with more pounds of air entering the
machine. The evaporative cooler achieves this goal in the summer time by cooling the inlet air when
ambient air temperatures are high.

1.3.3 Heat Recovery Steam Generators with Duct Burners

REC will use two HRSGs, one for each CT, which will utilize waste heat energy to increase electricity
production. The HRSGs systems extract heat from the exhaust of each gas turbine. The HRSG acts as a
heat exchanger to derive heat energy from the CT exhaust gas to produce steam that will be used to
drive a steam turbine generator. Exhaust gas entering the HRSG at approximately 1,100°F will be
cooled to approximately 180 °F by the time it exits the HRSG exhaust stack. With the exception of the
GE power block, steam production in the HRSGs may be augmented using duct burners (DBs) that will
be fired by natural gas. The proposed DBs will have a firing rate of 695 (HHV) MMBtu/hr each for the
Siemens SGT6-8000H and 435 (HHV) MMBtu/hr each for the MHPSA M501J.

REC’s selective catalytic reduction (SCR) and oxidation catalysts will be installed within the HRSG to
control NOx and CO, respectively.

A Continuous Emissions Monitoring System (CEMS) for monitoring emissions of NOx, CO, and
concentration of O or CO will be installed on REC’s HRSG exhaust stack.
2 2

1.3.4 Steam Turbine Generator

Each power block will include a reheat, condensing steam turbine designed for variable pressure
operation. The high-pressure section of the steam turbine receives high-pressure super-heated steam
from the HRSGs, and exhausts to the reheat section of the HRSGs. The steam from the HRSGs reheat
section is supplied to the intermediate-pressure section of the turbine, which expands to the low-pressure
section. The low-pressure section of the turbine also receives excess low-pressure superheated steam
from the HRSGs and exhausts to the condenser for cooling. REC’s steam turbine sets are designed to
produce up to approximately 160 MW of electrical output at ISO conditions with duct firing for the
Siemens and MHPSA units.

1.3.5 Auxiliary Boilers

The proposed facility will include two auxiliary boilers, one per power block. The auxiliary boilers
provide sealing steam to the steam turbine generator during cold start-up and to warm up the steam
turbine generator rotor.

The auxiliary boiler steam will not be used to supplement the power generation of the CTs or steam
turbine. The proposed boilers will be fired with natural gas with a heat input rating of 30 MMBtu/hr.

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