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06-Klitzke Sidwell Jensen Presentation Part 123
06-Klitzke Sidwell Jensen Presentation Part 123
ALSTOM
Flue Gas
Desulfurization
Technologies
Agenda
z ALSTOM
ALSTOM Today
Transport
Energy
The global specialist in energy and transport infrastructure.
3
Power
Reorganized into three sectors:
z Power Service
No. 1 in service
Largest installed base of
equipment
z
Sales:
10.9 billion euros
Orders received:
8.4 billion euros
Power Environment
No. 1 in boilers, environmental
and hydro
New regulations driving market
growth
1920
Norsk Viftefabrikk
1988
ASEA
ABB
ABB
Brown Boveri
1989
Combustion Engineering
1997
Daneco
Alstom
ABB
AlstomEnergy
Energy 1999
ABB
ABB
ABBAlstom
AlstomPower
Power
2000
ALSTOM
ALSTOMPower
Power
1000 people worldwide with a 600 MEUR business
Process Technologies
z
Particulate Removal
Electrostatic precipitators (wet and dry) & SO3 conditioning
Fabric Filters
Who We Are
North America Business Region
Knoxville, TN USA (344)
Headquarters
Velizy, France
GLOBAL Experience
LOCAL Solutions
ENVIRONMENTAL Compliance
FGD Experience
Personnel
z
Oslo, Norway
Vaxjo, Sweden
Milan, Italy
Sydney, Australia
Kobe, Japan
Knoxville, USA
z
z
Plant
J.K. Spruce 1
Asnaes 5
Lin Kou 1&2
Cumberland 1&2
Clover 1&2
Conemaugh 1&2
Niles
Konin 7&8
Navajo 1,2,3
Sual 1&2
Melnik I
Compostilla II
Karlshamn
Mae Moh 4-7
Randers
Centralia 1 & 2
Homer City
Florina
MW % S
546 0.6
650 2.5
2x350 2.0
2x1300 4.0
2x440 1.7
2x936 2.8
133 3.5
110 1.0
3x803 0.6
2x609 1.0
6x55 2.0
330 1.8
340 3.5
4x150 2.4
2x40 2.0
2x730 1.0
692 3.7
330 3.0
Start-Up
1992
1993
1994
1994
1994/95
1995
1995
1997
1997-99
1998
1997
1997
1997
1999
1999
2001-02
2001
2003
Country
US
DK
TW
US
US
US
US
PL
US
PH
CZ
ES
SE
TH
DK
US
US
GR
SPRAY TOWER
ABSORBER
ELECTROSTATIC
PRECIPITATOR
TO BALL
MILL
MAKE-UP
WATER
TANK
RECLAIM WATER
TANK
LIMESTONE
HYDROCLONE
AIR
FROM MW
TANK
BALL MILL
Reagent: Limestone
Byproduct: Gypsum
Efficiency: >97%, High S
BELT FILTER
GYPSUM
Limestone/Forced Oxidation
CO2
(Carbon dioxide)
H 2O
(Water)
SO2
(Sulfur dioxide)
CaCO3
(Calcium carbonate,
limestone)
O2
CaSO42H2O
(Calcium sulfate,
gypsum)
(Oxygen)
Materials of construction:
Flake-lined steel
Rubber-lined steel
Stainless steel
Nickel-based alloys
FRP
Tile Lined
Reaction Tank
Limestone dissolution,
gypsum formation
Liquid Residence Time
Solids Residence Time
Conventional
PEP
z
z
Alstom proprietary
SO2 measurement inside absorber
1 inch space resolution
5 ppm SO2 resolution
SO2 Removal:
Availability
Gas Velocity:
No. Spray Elevations:
Spray Zone:
Spray Pumps:
Spare Absorber:
Absorber / Stack:
Mist Eliminators:
Materials:
Oxidation:
Reheat:
Byproduct:
97%-98%
97%-98%
13.1 ft/sec (4.0 m/sec)
3-4
High efficiency spray
zone; PEP, Increased
spray height
Increased capacity:
72,000+ gpm each
No
Combined
2+2 Plus, Koch,
Munters
Flakeglass or Rubber
Lined CS, SS or Alloy
C276 Roll-Clad
Lance Injection
No
Commercial gypsum
Limestone Preparation
Limestone grinding
Horizontal/vertical
wet ball mills
On-site vs. off-site
preparation
Product ground to
90-95% < 40 ; 3035% solids
Rubber-lined with
hardened steel balls
Requires:
High purity limestone (95-96%)
z High efficiency ESP
z 99+% oxidation
z Belt filter or centrifuge
z Cake washing/purge stream
z
Primary Dewatering
Gypsum Hydrocyclone:
z Heavy, coarse particles
to underflow to
secondary dewatering
z Lighter, fine particles to
overflow including
flyash, limestone
z No moving parts
Hydrocyclone
Slurry feed
Product
discharge
Integrated Scrubber/Stack
z
z
Absorber/chimney integrated
into single structure
Advantages:
Lower capital cost
Smaller footprint
Shorter construction duration
Range of Experience
Plant Size (MW):
Boiler Size (MW):
Fuel
Absorber Size (MW):
Sulfur Range (%):
SO2 Inlet Concentration:
SO2 Removal Efficiencies (%):
Reagent:
By-Product:
Reheat:
Chlorides (ppm):
FGD Make-Up Water:
175 to 2,600
130 to 1,300
Coal, lignite, Orimulsion, oil
130 to 700
0.5 to 4.5
5,200 ppm / 15,000 mg/Nm3
85 to 99
Limestone, Lime, Flyash
Gypsum, Landfill
Wet Stack, By-Pass, Indirect, Regenerative
1,000 to 120,000
River, Lake, Plant Waste, Seawater
Consortium Alliance:
absorbers, reagent prep,
dewatering, ductwork, ID
fan modifications, stack,
buildings, electrical, DCS
piping, BOP
Location
Washington, USA
Capacity
2 x 700 MW
Scheduled
Start-Up
Commercial
Operation
Fuel
SO2 Removal
91%
No. Absorbers
1 per boiler
3+1
Absorber Size
Byproduct
Wallboard gypsum
Highlights
30 mo. Schedule;
317LMN absorber
TransAlta
Centralia Units 1 & 2 - 2 x 700 MW
Lewis County, WA
Reaction Tank
Internal Spray
Headers
317 LMN
External Spray
Pipe
FRP
PEP
317 LMN
Outlet Duct
Recycle Pumps
Inlet Duct
Mist Eliminators
FRP, Munters
Mist Eliminator
Wash Pipe /
Nozzles
FRP
Oxidation Air
Lances
317 LMN
Turnkey: absorbers,
reagent prep,
foundations, dewatering,
ductwork, stack,
buildings, electrical,
piping, BOP, waste
water treatment
Location
Pennsylvania, USA
Capacity
1 x 650 MW
Start-Up
Sept 2001
Fuel
SO2 Removal
98%
No. Absorbers
4+1
Absorber Size
Byproduct
Wallboard gypsum
Highlights
50%
Spraying reactor
Lime milk
Fabric filter /
Electrostatic
precipitator
Spraying reactor
Fabric filter
Water
Fabric filter /
Electrostatic
Circulating fluidized precipitator
bed reactor
NID
- No separate reactor
- Dust separator = reactor
- No lime milk
- Absorbens: quick lime
Fabric filter
Water
Water
0%
z
z
z
z
z
TC
Recirculation
Water
Humidifier
60
Thin
slurry
50
Thick
slurry
40
30
20
Paste
10
NID
Free
flowing
dust
Wet/Dry Process
Adsorbed equilibrium
moisture
Gas flow
8 Operating range from 20,000 Nm3/h
8 Single Reactor module up to Nm3/h
8 Parallel reactors for higher flows
NID Advantages
z
z
z
z
z
z
z
Other
NID Equipment
Mixer/Hydrator
Recycle
Re
CaO
H2O
cy
cle
+
Dispersion Plate
(inside the Reactor)
Ca
Hydrator
(O
H)
Mixer
Lime
silo
CaO
Recycle
Water
Lime
Hydrator
Stage 1
Hydrator
Stage 2
Mixer
Mixer/Hydrator installation
I.
II.
III.
IV.
Fuel
Nm3/h
Year
Laziska, PL
Coal
2 x 518,000
96/97
Vaasa, FI
Diesel
145,000
1998
Nuremberg, DE
Coal
168,200
1999
Fifoots Point, UK
Coal
3 x 450,000
2000
Zhejiang #8, CN
Coal
330,000
2001
Petcoke
2 x 511,500
2002
Seward, US
Coal
2 x 930,000
2004
Gilbert, US
Coal
900,000
2004
Elektrenai #8, LI
Orimulsion
520,000
2004
HuaYingShan, CN
Coal
451.000
2003
Baotou #2, CN
Coal
850,000
2004
NID + ESP
TC
CaO
Water
Water
Hydrator
Flue gas from
Diesel engines
Mixer
Fabric Filter
TC
Water
Water
Hydrator
Mixer
End
Product
EWAG Nrnberg
Replacement of SDA with NID
EWAG Nrnberg
NID basic plant data
Power production
Main fuel
Flue gas flow
Temperature
Inlet SO2
Outlet SO2
Absorbent
Dust emission, outlet NID
End product conveying
End product
In operation
114 MWt
Coal
157 000 Nm3/h
140 C
1800 mg/Nm3
max. 180 mg/Nm3
CaO
max. 10 mg/Nm3
Dense phase pneumatic system
Landfill
Year 1999
2 x 120 MW
Coal, max 1.4% S
2 x 518.000 Nm3/h
165C
1,500 4,000 mg/Nm3
80% (guaranteed)
95% (measured)
CaO
22,000 mg/Nm3 (no precollector
50 mg/Nm3 (guaranteed)
15 mg/Nm3 (measured)
Stabilisate/fire prevention in coal mines
Dense phase pneumatic system
1,200 m (tested)
3 x 120 MW
Coal, 1.2% S
3 x 450.000 Nm3/h
133C
800 ppm
80% (guaranteed)
CaO
25 mg/Nm3 (guaranteed)
Dense phase pneumatic system
Seward, USA
NID for CFB 2*250 MW
Seward, USA
NID - Technical data
Type
Size
Gas flow
In operation
CFB + NID
2*250
2*906 000
Dec 2003
MWel
Nm/h
Emissions guarantees
Dust
SO2 emission
SO2 removal overall
(Boiler + NID)
10
318
95
mg/Nm
ppm
%
Successful applications
Seawater available
Low-medium sulfur content
ELECTROSTATIC
PRECIPITATOR
SEAWATER
TREATMENT PLANT
SEAWATER
RETURN
SEAWATER FROM
BOILER CONDENSERS
AIR
Reagent: None
Byproduct: None
Efficiency: >95%, Low/Med. S
Process flow
Absorber design
Seawater FGD
z Utilizes
natural
alkalinity of seawater
z High efficiency via
packed tower
z No reagent, no
byproduct
z Effluent treated via
oxidation prior to
discharge
Fuel
MW
Start-Up
UNELCO
Tenerife, SP
Shenzhen West Power
Unit 4, CN
Mitsui
Paiton, ID
TNBJ Manjung, MY
Oil
2 x 160
1995
Coal
300
1998
Coal
2 x 670
1998/1999
Coal
3 x 700
2002/2003
2 x 300
2004
130
2005
Summary
FGD Alternatives
Installed
Capacity
First Installation
Reagent
Byproduct
Sulfur
Removal
Efficiency
Footprint
Pros
Cons
WFGD
33,000 MW
DFGD - SDA
12,000 MW
1968
Limestone
1980
Lime
DFGD - NID
3,000 MW
SWFGD
8,000 MW
1996
1968
Lime
Seawater
(Limestone with CFB)
Salable gypsum or
Landfill
Landfill or Use in
Treated Seawater
landfill
Cement/Road Constr
<6%
<2.5%
<6%
<2%
>98%
90-95%
90-95%
>95%
(98% w/CFB)
Small in power island Large in power island Small in power island Small in power island
area; large overall
area; small overall
area and overall
area; moderate
overall
No reagent
Low capital cost
Low capital cost
Low cost reagent
No byproduct
Low power
Low power
Marketable
consumption
consumption
byproduct
Fuel flexibility
Dry byproduct
Large reference list Dry byproduct
Operational
Operational
Fuel flexibility
simplicity, low
simplicity, medium
Ease of retrofit
maintenance costs
maintenance costs
Moderate capital
High cost reagent
High cost reagent
High capital cost
cost
Byproduct use
Byproduct use
High power
Effluent discharge
limited
limited
consumption
Limited applicability
Why ALSTOM?
z
z
z
New Developments
No Recycle Pumps
Energy from
oxidation blower
and fan used in
place of recycle
pumps.
Flowpac Advantages
No scaling or corrosion
problems
Karlshamn - Sweden