Wet Flue Gas Desulphurization System Flue Gas Desulphurization System March 12, 2012 ... steam generators and other products ... 500MW MATSUURA #1

Babcock-Hitachi K.K. 1All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Wet Flue Gas Desulphurization SystemWet Flue Gas Desulphurization System

MarchMarch 1122, 2012, 2012

BabcockBabcock--Hitachi K.K.Hitachi K.K.

Promising to contribute to global welfare Promising to contribute to global welfare with technologies of energy and environment systemswith technologies of energy and environment systems

Introduction of BabcockIntroduction of Babcock--Hitachi K.K.Hitachi K.K.


1. General Information1. General Information


BabcockBabcock--Hitachi in HITACH GroupHitachi in HITACH Group

PresidentPresident Corporate StaffCorporate Staff

Intellectual Property DivisionIntellectual Property Division

R&D DivisionR&D Division

Power Systems Company

Power Systems Power Systems CompanyCompany

Information & Control Systems CompanyInformation & Control Systems Company

Urban Planning & Development Systems CompanyUrban Planning & Development Systems Company

Industrial & Social Infrastructure Systems CompanyIndustrial & Social Infrastructure Systems Company

Mr. Hiroaki Nakanishi

Hydroelectric PowerSystems Division

Hydroelectric PowerHydroelectric PowerSystems DivisionSystems Division

Nuclear Systems DivisionNuclear Nuclear Systems DivisionSystems Division

Thermal PowerSystems DivisionThermal PowerThermal Power

Systems DivisionSystems Division

Power & Industrial Systems Division

Power & Industrial Power & Industrial Systems DivisionSystems Division

Boiler and Air Quality ControlSystems Division

Boiler and Air Quality ControlBoiler and Air Quality ControlSystems DivisionSystems Division

Babcock – Hitachi(100% Owned)

Babcock Babcock –– HitachiHitachi(100% Owned)

Mr. Tetsuro Wakino


Power Systems Company of HITACHIPower Systems Company of HITACHI

Nuclear Power Business Others

Thermal Power Business

Central Control Panel

(ABWR, ESBWR)

Preventive Maintenance, Fuel Cycle, etc.

Wind Power Sys. Solar Power Sys.

Hydro Power Sys.

Power Device

PBT Smart Grid,Transmission & Distribution SystemPET Service, etc.

AQCSCoal Fired PP

GTCC, Preventive Maintenance, etc.

Gas TurbineCO2 Capture Solution

Nuclear EquipmentRPV＜Major Equipment＞

20%20%

FY2010SALES¥813.2B

60%

Blue : Products of BHK


Outline of BabcockOutline of Babcock--Hitachi K.K.Hitachi K.K.

- Established 1953

- Employees 3,200 (Worldwide)

- Head Office Tokyo, Japan

- WorksKure 1st & 2nd, Noumi, AkitsuPhilippine (BHPI), China (BHDB)

- LaboratoriesKure, Akitsu

- Affiliated CompaniesDomestic : 2 / Overseas :3

- Quality CertificatesISO 9001, ISO 14001, ASME S, U and U2

Babcock-Hitachi K.K.

Segment of Power & Environmental

in Hitachi groupStock holder: Hitachi Ltd. (100%)


Company HistoryCompany History

Hitachi, Ltd.Hitachi, Ltd. B&W UKB&W UK19081908192719271928192819531953195919591961196119641964196519651971197119751975197819781987198719951995

BabcockBabcock--Hitachi establishedHitachi established

Kure Branch Works became independent from Hitachi WorksKure Branch Works became independent from Hitachi Works

Totally independent from Hitachi Ltd. Totally independent from Hitachi Ltd.

Corporate name changed to Corporate name changed to Toyo Babcock Ltd. Toyo Babcock Ltd.

Hitachi Works Boiler Manufacturing Hitachi Works Boiler Manufacturing Department establishedDepartment established

Hitachi Works Kure Branch Works establishedHitachi Works Kure Branch Works established

Zenma Works Ltd. Zenma Works Ltd. establishedestablished

[Expansion on Production Locations]1987 Akitsu Works1989 Noumi Works1989 Philippines (BHPI)1996 China (BHDB)

[Expansion on Production Locations]1987 Akitsu Works1989 Noumi Works1989 Philippines (BHPI)1996 China (BHDB)

Merged Merged （（CapitalCapital……¥¥1,235million1,235million））

Share Holding Ratio amounted to Share Holding Ratio amounted to 100% of Hitachi, Ltd.100% of Hitachi, Ltd.

(Capital(Capital……¥¥ 1,852.5 million)1,852.5 million)

(Capital(Capital……¥¥ 2,637.5 million)2,637.5 million)

(Capital(Capital……¥¥ 3,000 million)3,000 million)

(Capital(Capital……¥¥ 5,000 million)5,000 million)

2005200520062006

Hitachi Power Systems America (HPSA) establishedHitachi Power Systems America (HPSA) establishedBabcock Babcock BorsigBorsig Power Systems (BBPS ) acquiredPower Systems (BBPS ) acquired20032003

20112011Hitachi Power Europe (HPE) establishedHitachi Power Europe (HPE) established


Main ProductsMain Products

Integrated & Dedicated

Product Line-up forPower and Industrial

Plant

Power Boilers

HRSG

Industrial Boiler FGD SCR Nuclear Power

Industrial Plants

Incinerators


Kure First WorksKure, Hiroshima, JapanDesign and manufacturing of boilers

Head office

Kure Second WorksKure, Hiroshima, JapanManufacturing of nuclear power related products

Akitsu WorksHigashihiroshima, Hiroshima, JapanManufacturing of catalysts

Noumi WorksEdajima, Hiroshima, JapanManufacturing of heat recovery steam generators and other products

Office & Works in JapanOffice & Works in Japan

Location: Akihabara UDX Building, Tokyo Japan


As a core company of the HITACHI/Power&Industrial group, we provide boiler and AQCS services globally

Global Network

HITACHI Global Network for Boiler and AQCSHITACHI Global Network for Boiler and AQCS


Hitachi Power Systems America, Ltd. (HPSA)Basking Ridge, NJ, USA

Engineering, procurement and sales of boilers and Air Quality Control System (AQCS)

Hitachi Power Europe GmbH (HPE)Duisburg, Germany

Engineering, procurement, manufacturing and sales of boilers, AQCS and related equipment.

Works WorldwideWorks Worldwide


FGD retrofits FGD retrofits ––HITACHI formationHITACHI formation

Local partner

Sub-Contractors

Joint & SeveralConsortium

Babcock-Hitachi K.K.Hitachi Power Europe

Customer

EPC contract


Knauf Gips KG

Sub-Contractors

Babcock Hitachi K.K.Hitachi Power Europe GmbH

EPC contractOff-take contract

Cooperation

FGD retrofits FGD retrofits –– complete solution on cooperation with complete solution on cooperation with KnaufKnauf GipsGips

Customer


Knauf Reference ExampleKnauf Reference Example

Gypsum wall board plant near the power station

power station FGD Gypsum

store

Gypsum Wall Board plant


Status of Status of emissionemission standardsstandards in Europein Europe


Japanese regulation of flue gas treatmentJapanese regulation of flue gas treatment

Dust： 20mg/m3NDus

t Con

c. (m

g/N

m³)

SO2

Con

c. (p

pm)

1980 1990 1995 2000 2005 2010

20

40

60

80

100

0(Year)

10mg/m3N

～～

Dust:5 mg/Nm3

SO2:100ppm (285mg/Nm³)

SO2:25 ppm (71mg/Nm³) Dust:10mg/Nm3

NOx:35ppm (71mg/Nm³)

SO2：50ppm (142mg/Nm³)NOx：50ppm (103mg/Nm³)

Dust:20mg/Nm3

NOx:70ppm (144mg/Nm³)


Air Quality Control System (AQCS)Air Quality Control System (AQCS)

BoilerDeNOx(SCR) FGD

ESP

FGD : Flue Gas Desulfurization

BoilersDeNOx(SCR)

ESP

FGD

Stack

Hitachi is one of few AQCS Supplier

for total system

Hitachi is one of few AQCS Supplier

for total system

AQCSAir Quality Control Systems Stacks

(Layout for 1000MW coal fired plant in Japan)

A/H


Measures for SOMeasures for SO22 ReductionReduction

Circulating Dry Scrubber (CDS)Limestone Injection into Furnace and FlueGas Humidification

Activated coke method

Sea water methodMagnesium Hydroxide -Gypsum methodWet ProcessLimestone-Gypsum method

Spray Dryer Absorber (SDA)

Semi-Dry Process

Fly ash method

Activated carbon method

Dry Process


Reasons for the wide application of Wet Limestone-Gypsum Process

1) Limestone* is ・ Cheapest Absorbent・ Abundant in nature・ Easy Handling

2) Gypsum is ・ Useful for Cement Additives・ Useful for Wallboard Materials・ Easy Storing・ Easy Handling

3) The System is ・ Simple・ Easy to Operate・ High Reliability ・ High efficiency

FGD Process:FGD Process: Wet LimestoneWet Limestone--Gypsum ProcessGypsum Process

* also quick lime technology available (Walsum Power Plant - Branntkalk)

Technical Response to Emission regulations

Forced oxidation limestone gypsum process as almost standard technology(after technological and economical comparison)

Performance optimisation and cost reduction results in highly standardised absorber


2. Babcock-Hitachi’s WFGD Technology


Development of Hitachi WFGD SystemDevelopment of Hitachi WFGD System

PERFORATEDTRAY TOWER

SPRAY TOWER

R&D / PILOT

ADVANCED SPRAY TOWER

MATSUURA #1 – 1,000MW TACHIBANAWAN #2 – 1,050MWMATSUSHIMA #2 – 500MW

TRAY TOWER SPRAY TOWER ADVANCED SPRAY TOWER

1962 1970 1975 1995 2000 20051980

PERFORATED TRAY TOWER SPRAY TOWERADVANCED SPRAY TOWER

Initial StageImprovement of Reliability

Targeting Low Utility and CostReduction of Utility

TAMASHIMA #3 – 500MW

2010

LIMESTONE GYPSUM FGD SYSTEM

2015

Simplification of the System

Meeting Middle Load Ope.

1985 1990

COMMERCIAL PLANT ( Total 15, - COAL 3, OIL 12 )

COMMERCIAL PLANT ( Total 9, - COAL 4, OIL 3, COM 1, PET COKE 1 )

COMMERCIAL PLANT ( Total 52, - COAL 41, Lignite 3 ORIMULSION 2, OIL 2, PET COKE 2, R.O. 2 )


BHK FGD can be applied to any kinds of fuel and

various sulfur containing fuel

・Applied many kinds of fuel・Experience of high sulfur fuel

Wide Application of BHK WFGD SystemWide Application of BHK WFGD System

OIL

BHK FGD SYSTEM

ORIMULSION P. C.

FUELBHK'S EXPERIENCE1. OIL2. COAL3. COM4. ORIMULSION5. RESIDUE OIL6. PET.COKE

1000 2000 500040003000INLET SO2 CONCENTRATION (ppm)

COAL / LIGNITE

RESIDUAL OIL


PriPrinciple and System Flow nciple and System Flow ofof BHK Wet FGD SystemBHK Wet FGD System

WASTE WATER

ABSORBER

AIR

BOILERESP

GAS-GAS HEATER

STACK

LIMESTONE

GYPSUM DEWATERING

GYPSUM

FAN

LIMESTONE MILL

ABSORPTION SYSTEM GYPSUM RECOVERY SYSTEM

LIMESTONE PREPARATION SYSTEM

SO2+2H2O+CaCO3 (LIMESTONE) + 1/2O2 → CaSO4•2H2O(GYPSUM)+CO2

CHEMICAL PRINCIPLE: SO2 Absorption and Oxidation


Absorption systemAbsorption system



WASTE WATER

ABSORBER

AIR

BOILERESP

GAS-GAS HEATER

STACK

LIMESTONE

GYPSUM DEWATERING

GYPSUM

FAN

LIMESTONE MILL




ABSORPTION AREA

GAS

CLEAN GAS

FLUE GAS

AIRTANK AREA

TANK AREA

AIR ;

(GYPSUM)(LIMESTONE)

･

FLUE GAS：SO2

SO2+2H2O+CaCO3+1/2O2→CaSO4･2H2O+CO2

Pso2

Xso2

SPRAY NOZZLE

SLURRY GAS FILM

LIQUID FILMDROPLET DROPLET

Principle of BHK Advanced WFGD SystemPrinciple of BHK Advanced WFGD System

CHEMICAL REACTION

SO2 Absorption and Oxidation SO2+2H2O+CaCO3 (LIMESTONE) + 1/2O2 CaSO4•2H2O(GYPSUM)+CO2

ABSORPTION AREA

(Chemical Reaction in Absorber)(Chemical Reaction in Absorber)


Outline of Babcock HitachiOutline of Babcock Hitachi’’s Absorbers Absorber

<Air Dispersion>

<Oxidation Agitator>

<Spray Nozzles>

<Spray Header>


Absorber DesignAbsorber Design

Absorber Outlet(horizontal or vertical)

Absorber Inlet

Mist Eliminator(2 – 3 stages, depending from allowable drop content)

Spray Levels(number of levels depending on sulphur in fuel, if desired with space for retrofit of spare level)

Absorber sump(with agitator for mixing and oxidation air injection)

Spray Nozzles(up and/or down spray nozzles)

Absorption Area

SO2 & Dust Removal

Absorber Sump

Oxidation

Dissolution of Limestone

Crystal growth


Spec. A Rubber lined 2 x 6 mm

Spec. B Rubber lined 1 x 6 mm

Spec. C Alloy plated

European Solution: Rubber Lined Absorber

Lifetime of more than 50.000 hours, Maintenance and repair of coating by rubber lining specialist company only !

Absorber Material Absorber Material –– Rubber Lining ApplicationRubber Lining Application


Absorber Material Absorber Material –– Flake Lining ApplicationFlake Lining Application

Acid Resistant FRLHeat Resistant FRL

Heat Resistant FRL or Metal lined

Wear Resistant FRL or Metal lined

Spark test: Inspection of lining

Primer

1st layer2nd layerTop coat

Inspection After 3 Years Operation


Limestone Slurry preparation systemLimestone Slurry preparation system



WASTE WATER

ABSORBER

AIR

BOILERESP

GAS-GAS HEATER

STACK

LIMESTONE

GYPSUM DEWATERING

GYPSUM

FAN

LIMESTONE MILL


LIMESTONE SLURRY PREPARATION SYSTEM


Flow Diagram of Flow Diagram of Limestone Slurry Preparation SystemLimestone Slurry Preparation System

LimestoneFeeder

H/CClassifier

Mill TankSlurry Pump

Limestone

Limestone Slurry Tank

SiloGrinding/ Dilution

Water Supply

DistributionSystem

M

M

M

M

High

Low

WW

W

W

WWater

Main Process

W

W

Ball Mill


Limestone Preparation Limestone Preparation -- Wet Ball MillWet Ball Mill

- Quarry Ground Limestone or On-Site Mill

- Horizontal Ball Mill or Tower Mill

- 95% - 325 Mesh (44 µm)

- 30% Solids

H2S

O4

cons

umpt

ion

(= L

imes

tone

Rea

ctiv

ity)

Time

Standard

HorizontalBall Mill

Photo Horizontal Ball Mill

<Before Project Start >Evaluation of Limestone activity

Reliable Design

･Limestone Activity Test


Gypsum Recovery SystemGypsum Recovery System



WASTE WATER

ABSORBER

AIR

BOILERESP

GAS-GAS HEATER

STACK

LIMESTONE

GYPSUM DEWATERING

GYPSUM

FAN

LIMESTONE MILL




Hydro-Cyclone

OverflowAbsorber Slurry

Filtrate Receiver Vacuum PumpTo Absorber

Horizontal Belt Filter

Gypsum Recovery SystemGypsum Recovery System-- Belt Filter ApplicationBelt Filter Application

Water for recycling

By product Gypsum


Hydrocyclone

Vacuum Belt Filter

Byproduct Gypsum

Slurry feed

Direction

Vacuum

Gypsum Recovery SystemGypsum Recovery System-- Belt Filter ApplicationBelt Filter Application


BY-PRODUCT GYPSUM QUALITY

PHOTO OF BYPRODUCT GYPSUM CRYSTAL

——0.32 %CaＣO3

5~8—6.8pH

0. 03 %—0.001 %Na+

< 0. 25 %—< 0.05 %CaSO3 • 1/2H2O

> 95 %> 90 %98.8 %CaSO4 •2H2O

FOR WALL BOARD

FOR CEMENT

ACTUAL VALUEITEM

GENERAL REQUIREMENT IN JAPAN

Typical Requirement of Gypsum UsageTypical Requirement of Gypsum Usage


NeutralOdour

Non-toxicToxicity

5-9pH

< 0.01Cl

< 0.06Na2O

< 0.10MgO

> 95%CaSO4 •2H2O

WhiteColor

< 0.50 %CaSO3 • 1/2H2O

< 10%H2O

EURO GYPSUM CriteriaITEM

VGB-M 701e:EURO GYPSUM: Quality Criteria and analysis methods

Requirement of Gypsum Quality in EuropeRequirement of Gypsum Quality in Europe

BY-PRODUCT GYPSUM QUALITY


Large Flue Gas Volume

High SO2 Content

High Fly Ash Loading

High Inlet Gas Temperature High Inlet Moisture

FGD Design Consideration for Lignite CoalFGD Design Consideration for Lignite Coal

*1 Gas Flow Rate shall be confirmed.

High Removal Efficiency

High Absorber SlurryTemperature


BHK Unique FGD Technology: BHK Unique FGD Technology: Wet Stack SolutionWet Stack Solution

Wet stack on top of AbsorberWet stack on top of Absorber Stand alone Wet stackStand alone Wet stack

Features of “Wet Stack on top of Absorber”(1) Small-footprint

(2) Isolated from Absorber

Supported by Steel structure and

no load to absorber shell

Absorber

Wet Stack

Absorber

FRP Wet Stack


FGD Waste Water Treatment FlowchartFGD Waste Water Treatment Flowchart(Example in Europe)(Example in Europe)

COAGULANT

Sludge Storage Tank

Filter Press

Discharge to River

Ca(OH)2 Polymer HCl

RawFGD

WasteWater

TMT-15 FeCl3

LamellaClarifier

Waste Product

SS, Heavy Metals Removal

NeutralizationTank 1

NeutralizationTank 2

FlocculationTank

Treated Waste Water Tank

Cooling water


3. Experiences


HITACHIHITACHI’’ss FGD Experiences in Europe FGD Experiences in Europe

(800MW x 4)(750MW x 1)(800MW x 2)

(800MW x 1)

(220MW x 1)

(556MW x 1)


POWER’s 2011 Plant of the Year- Power Magazine (Oct 2011)

Project of the Year Award- Power Gen International 2011 in Las Vegas, USA

Reference Plant Industry RecognitionReference Plant Industry Recognition

Ameren Services (USA) / Coffeen Power Plant / No. 1, 2Ameren Services (USA) / Coffeen Power Plant / No. 1, 2


4. Research & Development4. Research & Development


R&D FacilitiesR&D Facilities

Desulfurization Test FacilityDesulfurization Test Facility Boiler-AQCS Pilot Test FacilityBoiler-AQCS Pilot Test Facility

Flue gastreatment facility

DESPCombustion facility

Coal Feed Rate 100~150 kg/hGas Flow Rate 1,000~1500 m3N/hAbs. dia: 480 mm

WFGD SCR

FF WESP

Burner

SCR

GGH

DESPPump

WFGD

Coal

BUFIDF

WESP

G/C

GGH

FF

CEM

4 Absorbers and 1 Reaction Tank Test Facilities

e.g.Absorber A Absorber B-Gas flow: 22,000m3N/h -Gas flow: 250m3N/h-SO2 conc.: 500 ppm -SO2 conc.: 20,000ppm-Abs. dia.: 680mm -Abs. dia.: 160mm

Absorber A Absorber B


< Model Consideration >- Spray Droplets- Kinetic Momentum (Droplet/Gas)

Gas Distribution

Confirmation of Optimized Absorber internal arrangements by Flow Model to prevent the gas short-pass.

Flow Model Results

Track of Spray Droplet

Computational Flow ModelComputational Flow Model


5. Conclusions


・Total Engineering Capability with Boiler Plant Engineering corresponding to various kinds of fuel

・Best-Mix of Japanese & European “State of the Art” Technologies

・Excellent Advanced Spray Tower Absorber Design featuring;a) Higher SO2 Removal Efficiency & Dust Removal Efficiencyb) Lower Gas Pressure Drop → Less Boost-Up Fan Capacityc) Excellent Liquid/Gas Contact → Less Recirc. Pump Capacityd) Higher Quality of By-Product Gypsum

→ Re-Use for Cement Additive and/or Wall Board Material

・Full Support by R&D Facility

・Proven FGD Technology and High Reliability

Special Features of BHK FGD SystemSpecial Features of BHK FGD System


6. SCR Process


SCR ProcessSCR Process

・ 4NO + 4NH3 + O2 → 4N2 + 6H2O・ NO + NO2 + 2NH3 → 2N2 + 3H2O・ 6NO2 + 8NH3 → 7N2 + 12H2O

REACTION FORMULA

SCR ; SELECTIVE CATALYTIC REDUCTION

NOx

NOx

NOx

NH3

NH3

NH3

NOx

NOx

N2

N2

H2O

H2O

H2O

CATALYST

CLEANGAS

NH3

Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Scheme of SCR SystemScheme of SCR System

BOILER

ECOEP DeSOx

FDF

STACK

NOx ANALYZER

BOILER LOAD

SIGNAL

NH3 STORAGE TANK

EVAPORATOR

ACCUMULATORFICMIXER

SCR ReactorNH3 injection

Catalyst

NH3 Storage & Supply


Reactor Design


SCR reactor

SCR Retrofit to Existing boiler

SCR Retrofit ExampleSCR Retrofit Example

APH

APHESP

ESP


SCR Reactor SCR Reactor

SUPPORTING STRUCTURE

CASING

NH3 INJECTION GRID

INLET DUCT

MAIN MONORAIL

HOIST

OUTLET DUCT

CATALYST BLOCK


CATALYST BLOCKCATALYST UNIT

CATALYST ELEMENT

Plate Type CatalystPlate Type Catalyst


Documents

Wet Flue Gas Desulphurization System Flue Gas Desulphurization System March 12, 2012 ... steam generators and other products ... 500MW MATSUURA #1