Different aspects to consider selecting FGD type of technology

Different aspects to consider
selecting FGD type of technology
Lars-Erik Johansson
Power-Gen India & Central Asia, 19-21 April, 2012, New Delhi, India
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
Page 2
© 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.
Emissions to Air and its Effects
Page 3
© 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.
WHO air quality guidelines
for major air pollutants
Page 4
© 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.
SO2 Emission Requirements (mg/Nm3)
National
Standards
U.S.
W. Europe
E. Europe
Pacific
Japan
Taiwan
South Korea
China
Current
Requirement
250 (50) (3-4 y)
400
400 - Uncapped
Case-By-Case
170-860
1430
100-200
100-200 (50)
<200
<200
<400
<400
<200
<400
Efficiencies requested from 80 % up to 98 %
Page 5
© 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.
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 Lo ndon Smog o f 1952
•Battersea power station – site of first
FGD
•2008: Newly unveiled plan for Battersea
Power Station
Page 6
© 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.
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
Page 7
© 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.
Most common principles for
Flue Gas Desulphurisation (FGD)
FGD options
WET FGD
Flue Gas
Desulphurisation
FGD type
End Product
Open Spray Tower
Lime/Lime Stone
Gypsum
Bubbling bed/
Tray absorber
Lime/Lime Stone
Gypsum
FGD Absorber
Sea water
None
Spray Dryer
Absorber
Sulphite
Circulating
Dry Scrubber/
NID
Sulphite
Dry Options
(DFGD)
Page 8
© 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.
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
Page 9
© 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.
Limestone WFGD Process Diagram
•STACK
ABSORBER
•WATER
•SPRAY TOWER
ABSORBER
•ELECTROSTATIC
PRECIPITATOR
•TO BALL
MILL
•MAKE-UP
WATER
TANK
•CHLORIDE
PURGE
•LIMESTONE
•HYDROCLONE
•AIR
•BELT FILTER
•GYPSUM
•FROM MW
TANK
DEWATERING
•BALL MILL
REAGENT
PREPARATION
Page 10
© 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.
Limestone/Forced Oxidation
CO2
(Carbon dioxide)
H2O
(Water)
SO2
(Sulfur dioxide)
CaCO3
(Calcium carbonate,
limestone)
O2
CaSO4•2H2O
(Calcium sulfate,
gypsum)
(Oxygen)
SO2 + CaCO3 + ½O2 + H2O → CaSO4•2H2O + CO2
Page 11
© 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.
Typical LS WFGD
•CPS Energy, J.K. Spruce Unit 2, US, 750 MW
Page 12
© 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.
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
Page 13
© 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.
Spray Dryer Absorber
CaO + H2O -> Ca(OH)2 + heat
SO2 + Ca(OH)2(s) -> CaSO3.½H2O(s) + ½H2O
Page 14
© 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.
Spray Dryer Absorber
Atomizing of slurry into small droplet by atomizing disc
(shown) or two-media nozzles
Page 15
© 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.
NID™ Flow Schematics
Reactor
Mixing Zone
Injection Zone
Page 16
© 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.
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
Page 17
© 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.
Recent development using Modular Design
(NID-C)
•Unit
1
•Stack
•Unit
2
Modularization Offers Arrangement Flexibility and
adaption to larger sizes
Page 18
© 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.
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 allows
further pre-assembly
-
Fabric filter compartments
Inlet/outlet plenums
Modularization Lowers Construction Costs
Page 19
© 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.
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
DFGD, NID-C was most favourable evaluated, toward
other technologies
Page 20
© 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.
Sea Water Flue Gas Desulphurization
(SWFGD)
Sea Water
Flue
Gas
Dust
Collector
Sea Water
SO2
Absorber
Sea Water
Treatment
Plant
Reheat
Equipment
Clean
Flue
Gas
Air
Treated
Sea Water
Page 21
© 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.
Sea Water Flue Gas Desulphurization
(SWFGD)
SO2 + H2O ↔ SO32- + 2H+
(absorption)
H+ + HCO3- + ↔ CO2 + H2O
(neutralisation)
SO32-
(oxidation)
+ ½O2 → SO42-
• CO2
• H2O
• SO42Page 22
© 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.
Alstom SWFGD 3D Layout
GGH
ESP or FF
ID Fan
Absorber
Absorber
Pump
SWTP
Aeration
Fan
Booster Fan
Page 23
© 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.
Discharge seawater quality
Sea Water Treatment Plant is a key for good discharge
quality
Page 24
© 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.
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
Page 25
© 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.
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
Page 26
© 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.
Selecting FGD Technology
Economic aspects
•Capital cost
•Operating cost
Technical aspects
•Sulphur removal
•Reliability
•Space requirements
Commercial aspects
•Reliable supplier
•Proven technology
•Supplier guarantee
Page 27
© 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.
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
Page 28
© 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.
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
Page 29
© 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.
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
Page 30
© 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.
Typical key parameters for different
technologies - overview
Dry FGD
NID or SDA
1980
•
Low investment
cost
•
Dry by-product
•
Small footprint
•
Multi-pollutant
control
Seawater FGD
Packed Tower
1968
•
No reagent
•
No by-product
Limestone WFGD
Spray Tower
1968
•
High efficiency
spray zone
•
Low cost reagent
•
By-product flexibility
Reagent
By-product
Lime
Landfill
Seawater
Seawater
Sulfur
Removal
Efficiency
Capital Cost
<4.5 % (NID)
-98 % (NID)
<1.5 %
-98 %
Limestone
Marketable
landfill
<6 %
-99 %
0.7X
0.8X
X
0.7 %
Power
Consumption
(inc.
booster
fans)
0.7-1.5 %
1.0-2.0 %
Aborbent Cost
By-product Cost
€0/ton
€0/ton
€20/ton
€5-10/ton – disposal
(€5/ton) – sale
Absorber
First Installation
Features
€80/ton
€5-10/ton
gypsum
or
Page 31
© 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.
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
Page 32
© 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.
FGD Technology Selection - Overview
DFGD – NID technology has expanded the range to large
plants
Page 33
© 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.
Example NPV calculation for different
technologies
Each case must be evaluated with the specific
conditions
Page 34
© 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.
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
Page 35
© 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.
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
Page 36
© 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.
Questions ?
Thank You
Page 37
© 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.
www.alstom.com/power