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©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .1
Design&OperationofWetElectrostaticPrecipitators
XIMesaRedondadePlantas deAcidoSulfúricoOlmue’Chile
RalphCasaleEgbertVanEverdingenSamKumar
October23-27,2016
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .2
TheCoreofB&WStrongFoundation,Diversified,PositionedforGrowth
B&WMEGTEC KVB-Enertec™ DiamondPower®
SteamGenerationandEnvironmentalSolutions
• People, Safety, Excellence, Technologyand Stewardship
• 150 Years of Experience • Global Presence and Project Execution• Technology Innovation Powering Best-in-Class Portfolio• Highest Standards of Ethics, Integrity, Quality and Customer Satisfaction
Strength ofourVALUES
Value fromourSTRENGTHS
Boiler CleaningEquipment & Controls
EmissionsMonitoring Systems
Ash & MaterialHandling Systems
Allen-Sherman-Hoff®
IndustrialEnvironmental
Wet & DryCooling Systems
Renewable,Waste-to-Energy
B&W SPIGB&W Vølund
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .3
IndustrialEnvironmentalSolutionsEmission Technology Solution
ParticulateControl• PulseJetFabricFilter/Baghouse• WetandDryESPs• Multiclone® DustCollectors• WetParticulateScrubbers
NOX Control • SCR• SNCR
SO2 /AcidGasControl• WetScrubbers/AcidGasAbsorbers• SprayDryAbsorbers• DrySorbentInjection
AcidMistControl • WetESPs• DrySorbentInjection
VOC/CO/HAPControl• RegenerativeThermalOxidizers(RTOs)• RegenerativeCatalyticOxidizers(RCOs)• CatalyticRecuperativeOxidizers
Mercury,DioxinsandFurans
• PowderedActivatedCarbon(PAC)Injection• EvaporativeGasCooling&Conditioning
EmissionsMonitoring • ContinuousEmissionsMonitoringSystems(CEMS)• DataAcquisition&HandlingSystems(DAHS)
OdorControl• Oxidizers• AdsorptionSystems• BiologicalAbatement
Complete Portfolio of Advanced,
Integrated & CustomizedEmissions
ControlSolutions
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .4
B&WESPBusinessDevelopmentHistory
ê 1995- B&WacquiredJoyEnvironmentalTechnologies• 130wetESPinstallations• 800dryESPinstallations
ê 2004- B&WacquiredexclusiveworldwiderightsfromF.L.Smidth• 100wetESPreferences
ê B&WhasexecutedseveralwetanddryESPprojectsê 2010- B&WacquiredtheESPbusiness,Preciptech,fromGE-BHA• SeveralhundreddryESPupgrades• Severalthousandcontrollerupgrades
ê 2014- B&WacquiredMEGTECSystems• 80wetESPreferenceplantsofMEGTECTurboSonic
ê KeystafffromJoy,FLS,Preciptech,MEGTEC
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .5
ProgressinWetESPApplicationinAcidPlantsinlast20years
ê Commitmenttoservingsmelter-sulfuricacidplantsê Introductionofall-alloywetESPdesignsê IntroductionofadvancedSQcontrollersforpower
suppliesê Continuingmaterialsengineeringresearchê ContinuingwetESPperformanceenhancement
researchê Commitmenttoservice&upgradeofexistingdryand
wetESPs
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .6
MovingfromLeadtoAlloys– OldvsNew
OldwetESPdesignusingleadinternals
NewwetESPdesignusingalloyHEXtubesandRDEs
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .7
MovingfromLeadtoall-alloyhextubesNew module with 238
HEX tubes (10”)Old module with 100
round tubes (10”)
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .8
MoreWetESPPerformancePerFootprint
OldwetESP100tubes NewalloywetESP238tubes
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .9
5WetESPsinCopperSmelter- 2012
ALLOYHEXUNIT
20tons
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .10
Customer
Application Pet-CokeCalciner
ZincSulfuricAcidPlant
SpentAcidRegeneration
CopperAcidPlant
SpentAcidRegeneration
SpentAcidRegeneration
CopperAcidPlant
NickelAcidPlant
WESPunit 6HEXWESPAlloy904L
6HEXWESPAlloyC276
2HEXWESPAlloy904L
5HEXWESPAlloy6Mo
1HEXWESPAlloy6Mo
2HEXWESPAlloy6Mo
2HEXWESPAlloy31
4HEXWESPAlloyC22
Numberoftubes
238&248HEXtubesx17ft(5.18m)long
150HEXtubesx17ft(5.18m)
long
248HEXtubesx15ft(4.57m)
long
248HEXtubesx17ft(5.18m)
long
168HEXtubesx18ft(5.48m)
long
130HEXtubesx17ft(5.18m)
long
320HEXtubesx17ft(5.18m)
long
248HEXtubesx17ft(5.18m)
long
InOperationsince 1999 2000 2006 2012 2015 2015 Oct-2016
Startup
Equipmentdelivered,Startupinspring-2017
B&WMEGTECAlloyHEXWetESPUnitsonAcidMistApplications
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .11
B&WAlloyTubeBundleLiftedandFitintoanFRPShell
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .12
168HEXAlloy6MotubebundleinsertedintoexistingFRPshell
168HEXAlloy6MotubebundleshopfabricatedandbeinginsertedintoFRPvessel
RegenSulfuricAcidPlant:ReplaceInternals
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .13
Electrical:ê Powersupplydesign
ê HybridSQ-300®i
Mechanical:ê Newdischargeelectrodedesign
Software:ê Coronamapping
ê PrecipitatorManager™
ê PrecipRADAR™
SQ-300i3-PhaseAVC
DischargeElectrode CoronaMappingSoftware
SomeCurrentESP-relatedR&DatB&W
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .14
SQ-300®i SparkResponseSecondaryCurrentSignal(mA)
FastRamp
Setback(%belowspark)
Spark
Quench
SparkLevel
Spark
SlowRamp
tonextspark(SetbySparkRate)
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .15
3-PhaseLowRipplePowerSupplyIncreasesPowerOutput
Belowarefieldtestresultsbefore thereplacementofaconventionalsingle-phasepowersupply(inred),andafter, withtheB&W3-phaselowripplepowersupply(ingreen)
0
10
20
30
40
50
60
70
80
90
175 185 195 205 215 225 235 245 255 265 275
KW
MW
MWvs.KW(PreandPost3PhaseInstall)
1A-1KW(Pre)
1A-13ØKW(Post)
1A-1*
2A-13A-14A-1ESP
ChamberLayout
GasFlow
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .16
0%
20%
40%
60%
80%
100%
120%
0 30 60 90 120
150
180
210
240
270
300
330
Porcen
taje
deCorrie
nte
Degrees
0%
20%
40%
60%
80%
100%
120%
0 30 60 90 120
150
180
210
240
270
300
330
Porcen
taje
deCorrie
nte
Degrees
0%
20%
40%
60%
80%
100%
120%
0 30 60 90 120
150
180
210
240
270
300
330
Porcen
taje
deCorrie
nte
Degrees
Gained Power !
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .17
OngoingMaterialsR&DMaterialsTestingê Alloycoupontestingatleastsixdifferentsulfuricacidplantsê CarbonCompositematerialê OurCCMdesigndevelopmentincorporatestheconductive
compositeconcept.ê Noneedforcontinuousinjectionofdropletstomaintain
conductivity.ê Verygoodresultsonthetestedcouponinanacidplantforovera
yearê Arcingandsparkingresistanceissuperiortometals.
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .18
ArcTestingofComposite– Arc
Subjectedto13,000arcsonthesamelocationwithout any impacts
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .19
FailedPVCWetESPTube
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .20
FailedPVCWetESPTube
© 2010 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. .20
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .21
ê OptimizeESPgeometryforlowercapitalcosts
ê Maximizecoronapowerthroughsuperiorelectrodedesign
ê Maximizecoronapowerthroughsuperiorpowersupplies
ê Optimizeperformancethroughsuperiorpowersupplycontrols
ê Thepathforwardistocontinueourevaluationofeachcomponentoftheparticulatecollectionprocesssowemaydoabetterjobofapplyingthistechnologyworldwide.
PowerSupplyDesign
CoronaGeneration
CoronaCurrent
ParticulateCollection
EnhancePrecipitatorPerformanceWhileKeepingCostsinCheck
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .22
FeedbackfromGlobalESPClientsEssentialforContinuousImprovement
• Over16,000SQcontrollers
• Inover400plants• In52countries
©2016MEGTECSystems,Inc.Allrightsreserved.ProprietaryandConfidential. .23
Thankyouforyourattention.Anyquestions?
ContactMr.RalphCasaleSalesManager– LatinAmerica
Phone:(201)7233400Email:[email protected]
