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Different aspects to considerselecting FGD type of technology

Power-Gen India & Central Asia, 19-21 April, 2012, New Delhi, India

Lars-Erik Johansson

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 © 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 anyparticular 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, withoutexpress 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

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Page 3

Emissions to Air and its Effects

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Page 4

WHO air quality guidelinesfor major air pollutants

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Page 5

SO2 Emission Requirements (mg/Nm3)

U.S. 250 (50) (3-4 y) <200W. Europe 400 <200E. Europe 400 - Uncapped <400

Pacific Case-By-Case <400Japan 170-860 <200Taiwan 1430 <400

South Korea 100-200China 100-200 (50)

NationalStandards

CurrentRequirement

Efficiencies requested from 80 % up to 98 %

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Page 6

First utility FGD in the world: London,England

• Battersea Power Station - 1935

•Used alkaline Thames riverwater to scrub SO2

•Scrubber was made of wood

•Worked fine – Stopped due tothe plume

•Great London Smog of 1952

•2008: Newly unveiled plan for Battersea

Power Station

•Battersea power station – site of first

FGD

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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 incombination with a fabric filter

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Page 8

Most common principles forFlue Gas Desulphurisation (FGD)

Flue GasDesulphurisation

Open Spray TowerLime/Lime Stone

Bubbling bed/ Tray absorberLime/Lime Stone

FGD AbsorberSea water

Spray Dryer

Absorber

CirculatingDry Scrubber/ NID

Dry Options(DFGD)

WET FGD

Gypsum

Gypsum

None

Sulphite

Sulphite

End ProductFGD typeFGD options

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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

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Page 10

Limestone WFGD Process Diagram

•MAKE-UP

WATERTANK

•CHLORIDE

PURGE

•HYDROCLONE

•BELT FILTER

•SPRAY TOWERABSORBER

•ELECTROSTATICPRECIPITATOR

•STACK

•WATER

•AIR

•LIMESTONE

•BALL MILL

•TO BALLMILL

•FROM MWTANK

•GYPSUM

REAGENT

PREPARATION

ABSORBER

DEWATERING

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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

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Page 12

Typical LS WFGD

•CPS Energy, J.K. Spruce Unit 2, US, 750 MW

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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 oneor several high velocity sections (venturi’s)

- NID™Premixing of recycle solids and water

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Page 14

Spray Dryer Absorber

CaO + H2O -> Ca(OH)2 + heatSO2 + Ca(OH)2(s) -> CaSO3.½H2O(s) + ½H2O

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Page 15

Spray Dryer Absorber

Atomizing of slurry into small droplet by atomizing disc(shown) or two-media nozzles

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Page 16

NID™ Flow Schematics

Reactor

Mixing Zone

Injection Zone

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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 achieveemissions guarantees at full load

with one module out of service

Allows for Turn-Down up to 60% without Recirculation

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Page 18

Recent development using Modular Design(NID-C)

•Unit1

•Unit2

•Stack

Modularization Offers Arrangement Flexibility andadaption to larger sizes

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Page 20

DFGD, NID-C was most favourable evaluated, towardother 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

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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

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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-

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Page 23

Alstom SWFGD 3D Layout

AbsorberPump

AerationFan

ESP or FF

ID Fan Booster Fan

SWTPAbsorberGGH

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Page 24

Discharge seawater quality

Sea Water Treatment Plant is a key for good dischargequality

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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

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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

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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 

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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 withparticulate 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

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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

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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 ofgood 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 highCAPEX 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

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Page 31

Typical key parameters for differenttechnologies - overview

Dry FGD Seawater FGD Limestone WFGDAbsorber NID or SDA Packed Tower Spray Tower

First Installation 1980 1968 1968

Features   • Low investmentcost

• Dry by-product• Small footprint• Multi-pollutant

control

• No reagent• No by-product

• High efficiencyspray zone

• Low cost reagent• By-product flexibility

Reagent Lime Seawater Limestone

By-product Landfill Seawater Marketable gypsum orlandfill

Sulfur <4.5 % (NID) <1.5 % <6 %

RemovalEfficiency

-98 % (NID) -98 % -99 %

Capital Cost 0.7X 0.8X X

PowerConsumption(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

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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

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Page 33

FGD Technology Selection - Overview

DFGD – NID technology has expanded the range to largeplants

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Page 34

Example NPV calculation for differenttechnologies

Each case must be evaluated with the specificconditions

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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

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Page 36

Conclusions

• Many technologies has during the years been developedwith DFGD, LSWFGD and SWFGD as the preferred,most widely spread technologies

• All established technologies can meet the demands forSO2 removal for the Indian market

• All technologies have different consideration and oftenrelated to operation and capital cost transferred to NPV

• Specifically for low to medium range sulphur content, theDFGD and SWFGD will most probably be the preferredtotal evaluated technologies

Reliable technologies exist to meet the futuremarket in INDIA, but each case must be evaluated

Q i ?

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