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Different aspects to consider selecting FGD type of technology
Power-Gen India & Central Asia, 19-21 April, 2012, New Delhi, India
Lars-Erik Johansson
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 2
Agenda
• 1st topic Introduction and classification of FGD
• 2nd topic Different type of FGD with main features
• 3rd topic Different aspects for considerations
• 4th topic Examples of evaluations
• 5th topic Conclusions
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 3
Emissions to Air and its Effects
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 4
WHO air quality guidelines for major air pollutants
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 5
SO2 Emission Requirements (mg/Nm3)
U.S. 250 (50) (3-4 y) <200
W. Europe 400 <200
E. Europe 400 - Uncapped <400
Pacific Case-By-Case <400
Japan 170-860 <200
Taiwan 1430 <400
South Korea 100-200
China 100-200 (50)
NationalStandards
CurrentRequirement
Efficiencies requested from 80 % up to 98 %
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 6
First utility FGD in the world: London, England
• Battersea Power Station - 1935
•Used alkaline Thames river water to scrub SO2
•Scrubber was made of wood
•Worked fine – Stopped due to
the plume•Great London Smog o f 1952
•2008: Newly unveiled plan for Battersea
Power Station
•Battersea power station – site of first FGD
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 7
Classification of post-combustion FGD
• Wet systems- Operating at saturated conditions
- Using slurry or solution in the flue gas with nozzles to
create mass transfer between flue gas and liquid
• Complete dry systems- Introducing dry absorbent (lime or bicarbonate)
- Limited performance without controlling the temperature
• DFGD operation with controlled temperature- Spray dryer absorber – using a slurry
- Circulating Dry Scrubber or NID™ – using recycle solids in
combination with a fabric filter
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 8
Most common principles forFlue Gas Desulphurisation (FGD)
Flue Gas Desulphurisation
Open Spray Tower Lime/Lime Stone
Bubbling bed/Tray absorberLime/Lime Stone
FGD AbsorberSea water
Spray Dryer Absorber
Circulating Dry Scrubber/NID
Dry Options(DFGD)
WET FGD
Gypsum
Gypsum
None
Sulphite
Sulphite
End ProductFGD typeFGD options
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 9
Agenda
• 1st topic Introduction and classification of FGD
• 2nd topic Different type of FGD with main features
• 3rd topic Different aspects for considerations
• 4th topic Examples of evaluations
• 5th topic Conclusion
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 10
Limestone WFGD Process Diagram
•MAKE-UP
WATER
TANK
•CHLORIDE
PURGE
•HYDROCLONE
•BELT FILTER
•SPRAY TOWER
ABSORBER
•ELECTROSTATIC
PRECIPITATOR
•STACK
•WATER
•AIR
•LIMESTONE
•BALL MILL
•TO BALL
MILL
•FROM MW
TANK
•GYPSUM
REAGENT
PREPARATION
ABSORBER
DEWATERING
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 11
Limestone/Forced Oxidation
SO2
(Sulfur dioxide)
H2O(Water)
CaCO3
(Calcium carbonate, limestone)
O2
(Oxygen)
CaSO4•2H2O(Calcium sulfate,
gypsum)
CO2
(Carbon dioxide)
SO2 + CaCO3 + ½O2 + H2O →→→→ CaSO4•2H2O + CO2
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 12
Typical LS WFGD
•CPS Energy, J.K. Spruce Unit 2, US, 750 MW
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 13
DFGD – technology specific features
• Lime-based semi-dry FGD technology• Control the temperature to meet high performance• Multi-pollutant control: High efficiency removal of SO2,
SO3, PM, HCl, and HF• Fuel flexibility of up to 2.5% sulphur coal or higher
• Several types- Spray Dryer Absorber (SDA)
Slurry based
- Circulating Dry Scrubber (CDS)
Introducing water and recycle solids independently in one or several high velocity sections (venturi’s)
- NID™
Premixing of recycle solids and water
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 14
Spray Dryer Absorber
CaO + H2O -> Ca(OH)2 + heatSO2 + Ca(OH)2(s) -> CaSO3.½H2O(s) + ½H2O
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 15
Spray Dryer Absorber
Atomizing of slurry into small droplet by atomizing disc (shown) or two-media nozzles
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 16
NID™ Flow Schematics
Reactor
Mixing Zone
Injection Zone
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 17
NID-C Modular Concept
• Multiple, independently isolatable
modules• Dampers
- Upstream of reactor- Downstream of FF compartment
• Nominal gas flows corresponding
to 15 - 70 MWel per module
• Can be designed to achieve
emissions guarantees at full load
with one module out of service
Allows for Turn-Down up to 60% without Recirculation
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 18
Recent development using Modular Design (NID-C)
•Unit 1
•Unit
2
•Stack
Modularization Offers Arrangement Flexibility and adaption to larger sizes
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 19
Modular Design (NID-C)
• Shop fabrication drastically
cheaper than field fabrication
• Allows high degree of shop fabrication even with truck
shipment- Reactors
- Inlet ducts
- Day silos
- Mixers
- Hydrators
• Barge access allowsfurther pre-assembly
- Fabric filter compartments
- Inlet/outlet plenums
Modularization Lowers Construction Costs
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 20
DFGD, NID-C was most favourable evaluated, toward other technologies
Recent NID-C application
Location Indian River, US
Capacity 410 MW
Fuel Coal, 2,5 % S
SO2 removal 96 % (75 PPM)
Others HCl, SO3, HF
Particulate, Opacity
Start-up 2012
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 21
Sea Water Flue Gas Desulphurization (SWFGD)
FlueGas
DustCollector
SO
Absorber
Sea WaterTreatment
Plant
Air
TreatedSea Water
CleanFlueGas
Sea Water
Reheat
Equipment2
Sea Water
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 22
Sea Water Flue Gas Desulphurization (SWFGD)
SO2 + H2O ↔↔↔↔ SO32- + 2H+
(absorption)
H+ + HCO3- + ↔↔↔↔ CO2 + H2O
(neutralisation)
(oxidation)
SO32- + ½O2 →→→→ SO4
2-
• CO2
• H2O
• SO42-
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 23
Alstom SWFGD 3D Layout
Absorber Pump
Aeration Fan
ESP or FF
ID Fan Booster Fan
SWTPAbsorberGGH
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 24
Discharge seawater quality
Sea Water Treatment Plant is a key for good discharge quality
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 25
Haimen Power Plant
Location Haimen, P.R. China
Capacity 2 x 1000MW
Fuel Coal, 0.9 % S
Gas flow 3 426 000 Nm3/h
SO2 inlet 1960 mg/Nm3
(dry, 6% O2)
SO2 removal 95 %
Flue Gas Reheat GGH
Effluent pH >6.8
Start-up 2009
World’s Largest SWFGD for Unit Size
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 26
Agenda
• 1st topic Introduction and classification of FGD
• 2nd topic Different type of FGD with main features
• 3rd topic Different aspects for considerations
• 4th topic Examples of evaluations
• 5th topic Conclusions
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 27
Selecting FGD Technology
Economic aspects•Capital cost•Operating cost
Technical aspects•Sulphur removal
•Reliability
•Space requirements
Commercial aspects•Reliable supplier
•Proven technology
•Supplier guarantee
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 28
Selecting FGD technology – New or Existing
• Green-field- Space can be planned, but different technologies give
different layout demands
- Some (wet) FGD technologies must be complemented with
particulate separation
• Brown-field- Normally limitation in foot-print
- Existing AQCS-equipment and status have importance
- Reuse of stack
- Loss of revenue during installation
• Ready for retrofit- CO2 capture ready – space requirements
- Increased emission demands
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 29
Selecting FGD Technology - Emissions
• Emissions of SO2 and other acid components- Most technologies can handle the demands
• Liquid discharge- Access to release Cl rich water
• Particulate- DFGD technologies using fabric filters can handle the
particulate emissions
• Visible plume – dispersion of stack plume- DFGD operate at high temperature than wet systems
- Reheat might be needed for wet systems
- DFGD technologies have higher efficiencies on SO3 – to
meet low opacity
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 30
Selecting FGD Technology - Cost
• Absorbent material- DFGD needs quick lime with high quality to meet low
consumables and good control emissions
- Limestone, to be used within LS WFGD needs to be of
good commercial quality
- In case of sea water, access is needed – coastal areas
• NPV- All cost to be included in OPEX and CAPEX
- Discount rate and evaluation time
- High rate and long time favor technologies with relative high CAPEX and low OPEX
• Size of the plant- Consumptions is normally proportional to the size- Other operation normally less than proportional to the size
- Investment cost normally less than proportional to the size
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 31
Typical key parameters for different technologies - overview
Dry FGD Seawater FGD Limestone WFGDAbsorber NID or SDA Packed Tower Spray Tower
First Installation 1980 1968 1968
Features • Low investment cost
• Dry by-product
• Small footprint• Multi-pollutant
control
• No reagent• No by-product
• High efficiency spray zone
• Low cost reagent• By-product flexibility
Reagent Lime Seawater Limestone
By-product Landfill Seawater Marketable gypsum or landfill
Sulfur <4.5 % (NID) <1.5 % <6 %
Removal Efficiency
-98 % (NID) -98 % -99 %
Capital Cost 0.7X 0.8X X
Power Consumption (inc. booster fans)
0.7 % 0.7-1.5 % 1.0-2.0 %
Aborbent Cost €80/ton €0/ton €20/ton
By-product Cost €5-10/ton €0/ton €5-10/ton – disposal(€5/ton) – sale
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 32
Agenda
• 1st topic Introduction and classification of FGD
• 2nd topic Different type of FGD with main features
• 3rd topic Different aspects for considerations
• 4th topic Examples of evaluations
• 5th topic Conclusions
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 33
FGD Technology Selection - Overview
DFGD – NID technology has expanded the range to large plants
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 34
Example NPV calculation for different technologies
Each case must be evaluated with the specific conditions
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 35
Agenda
• 1st topic Introduction and classification of FGD
• 2nd topic Different type of FGD with main features
• 3rd topic Different aspects for considerations
• 4th topic Examples of evaluations
• 5th topic Conclusions
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 36
Conclusions
• Many technologies has during the years been developed with DFGD, LSWFGD and SWFGD as the preferred, most widely spread technologies
• All established technologies can meet the demands for SO2 removal for the Indian market
• All technologies have different consideration and often related to operation and capital cost transferred to NPV
• Specifically for low to medium range sulphur content, the DFGD and SWFGD will most probably be the preferred total evaluated technologies
Reliable technologies exist to meet the future market in INDIA, but each case must be evaluated
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Page 37
Questions ?
Thank You