Download - Entel Fgd Experiance
ENERGOPROJEKTENERGOPROJEKT--ENTELENTEL&&
FLUE GAS DESULHURIZATIONFLUE GAS DESULHURIZATION
Experiences, Challenges and Opportunities
OVERVIEW OF THE MAIN TOPICS
1. EPE activities on air pollution control and flue gas cleaning
2. Experiences in the application of FGD technologiestechnologies
3. Possibilities for EPE participation in FGD projects in Serbia and in the region
ACTIVITIES ON AIR QUALITY CONTROL AND FLUE GAS CLEANING IN COAL FIRED
THERMAL POWER PLANTS
Current projects (after adoption of ELVs)
Previous projects�High stacks enabling dispersion of pollutants and air
immisions control�Flue gas dust removal using ESP –efficiency up to 98-99 %
Current projects (after adoption of ELVs)� Flue gas dust removal using high efficiency ESP – up to
99,93 %� NOx emission reduction by application of primary
measures during the major boiler overhaul – low-NOx burners and OFA system, as well as NCSR using urea solution as reagent
�� SOSO22 emission reduction by application emission reduction by application flue gas flue gas desulphurization processdesulphurization process
BRIEF HISTORICAL REVIEW OFEPE ACTIVITIES IN SO2 REMOVAL
�� During During middle 19middle 1980s80s:
♦♦♦♦ TPP Kolubara B design: Analyses of possible FGD technologies to be implemented for the purpose of required area estimation
♦♦♦♦ General study on application of FGD technologies on TPPs in EPS
�� During During 191990s90s:
♦♦♦♦ TPP Kolubara B design: Selection of referent FGD technology for ♦♦♦♦ TPP Kolubara B design: Selection of referent FGD technology for TPPs in EPS in general and general design preparation based on wet limestone/gypsym process
�� During 2000sDuring 2000s:
♦♦♦♦ Implementation of FGD process in TENT A1&A2 reconstructionproject - general design
♦♦♦♦ Study on optimization of SO2 reduction in coal fired TPPs of EPS
♦♦♦♦ Participation in PFS and FS for FGD Plant at TPP Kostolac B (with general design and basuc design)
THE MAIN RESULTS AND BENEFITS FOR EPE
� To became familiar with FGD technologies� To follow contineously developments of the
main FGD technologies� To recognize the main companies in the
world of FGD technologies� To recognize the main companies in the
world of FGD technologies� To define the needs od EPS in FGD domain
and to propose optimal solutions� To make the opportunity to participate in
the future major FGD projects for EPS and in the region
PREVIOUS AND CURRENT COOPERATION WITH FGD COMPANIES
� Lurgi-Lentjes Bischoff for TPP Kolubara B -FGD Plant general design
� Mitchubishi Heavy Industries for TENT A1&A2 - FGD Plant general designA1&A2 - FGD Plant general design
� AE&E, ALSTOM and Rafako for Study on SO2
removal optimization � Worley Parsons (with AE&E) for TPP
Kostolac B - FGD Plant general and basic design
WHY IS WET LIMESTONE/GYPSUM FGD PROCESS CHOSEN AS REFERENCE FOR TPPs IN EPS?
� Suitable for coal fired in Serbian TPPs� Suitable for all unit capacities (up to 1000 MW)� Suitable for changes in SO2 removal efficiency due
to fuel quality changes� Suitable for changes of FGD Plant load without
influence on SO removal efficiency influence on SO2 removal efficiency � Great operation experience and continual
development of process performance � Decrease both in investment as well as in
maintenance and operational expenses� Small influence on the main power plant
technology� Possible sale of by-product
PERCENT SHARE OF FGD TECHNOLOGIES
5060708090
Wet
01020304050
U S A Other World
WetDryOther
STUDY ON OPTIMIZATION OF SO2 REDUCTION IN COAL FIRED TPPs IN EPS
� Evaluation of general layouts of FGD Plants foreach coal fired TPP in Serbia
� Evaluation of the needs of limestone (quantitiesand quality) and possibilities of supply fromdomestic resources
� Evaluation of investment costs� Evaluation of investment costs� Evaluation of O&M costs� Influence on the electrcity cost, �c/kWh,
�c/kgSO2 removed� Ranking of TPPs by priority of FGD Plants
installation
THE MAIN RESULTS AND BENEFITS FOR EPS
PARAMETERS FOR FGD PLANT TECHNICAL SOLUTION SELECTION
� Unit(s) capacity and age
� Expected range of flue gas flow rate
� Expected range of input SO2 concentrations� Expected range of input SO2 concentrations
� Existing way of flue gas discharge
� Available space within TPP site, including planned TPP systems upgradings and/or changes
COAL CHARACTERISTICS
Characteristic Unit
Thermal power plant
Nikola Tesla A i B Kolubara A Kostolac A i B Morava
Mean coal
quality
Lower coal
quality
Mean coal
quality
Lower coal
quality
Mean coal
quality
Lower coal
quality
Mean coal
quality
Lower coal
quality
Low heat value kJ/kg 6.608 6.018 8.100 7.200 7.648 6.285 8.000 7.200
Dust % 18,5 26,9 10,00 12,00 23,7 28,0 14,3 12,00
Moisture % 49,2 44,5 51,8 50,5 40,3 40,2 49,0 51,8Moisture % 49,2 44,5 51,8 50,5 40,3 40,2 49,0 51,8
Volatile % 20,1 18,2 23,2 22,4 - - 22,5 23,2
Total sulphur % 0,42 0,47 0,45 0,45 1,13 1,08 0,62 0,45
Sulphur emission rate 0,9 0,9 0,9 0,9 0,9 0,9 0,9 0,9
Carbon % 19,8 18,2 24,1 22,15 22,1 19,3 23,7 22,1
Oxygen % 9,6 7,4 10,2 10,2 8,9 8,4 10,0 10,2
Hydrogen % 2,1 2,0 2,3 2,1 2,1 1,9 2,1 2,1
Nitrogen % 0,6 0, 7 1,2 1,2 0,8 0,8 0,5 1,2
THERMAL POWER PLANTS FLUE GAS CHARACTERISTICS
ParametarThermal power plant
Nikola Tesla Kolubara A Morava Kostolac
SO2 concentrations, mg/m3 2.750 – 3.200 2.390 – 2.640 2.640 – 3.450 6.540 – 7.150
SO2 emission, kg/MWh 11,6 – 15,3 12,2 – 17,1 12,3 – 15,5 26,7 – 37,9
SO2 emission, kg/kJ 1,2 – 1,4 1,0 – 1,1 1,1 – 1,4 2,7 – 3,1
Flue gas flow, m3/kWh 8,9 – 9,9 10,4 – 14,1 9,0 – 9,6 9,3 – 10,7
Moisture content, % 23,6 – 24,2 22,0 – 23,2 21,4 – 23,2 19,9 – 21,5
Dust content, mg/m3∗∗∗∗ 50 200 – 400 800 50
Chlorine content, mg/m3∗∗∗∗ 20-60 20-60 20-60 15-60
∗ dry gas, 0°C, 1013 mbar, 6% O2
FGD DESIGN CONSIDERATION FOR LIGNITE COAL
� Large flue gas volume� High SO2 content & high removal efficiency� High fly ash loading� High fly ash loading� High inlet gas temperature� High inlet gas moisture
FGD PLANT - TECHNICAL SOLUTION OPTIONS
� Limestone delivery (powder or crashed limestone)
� By-product handling (usage or disposal)� By-product handling (usage or disposal)� Flue gas discharge (wet or dry stack) � Pressure drop solution
MAIN QUESTIONS TO BE DEFINEDBEFORE FINAL DEFINITION OF
FGD PLANT TECHNICAL SOLUTION
� Referent fuel characteristics� Operation span for Units A1&A2� Available space in relation to ash and slag
collection and transport system (new collection and transport system (new “thick” slurry system)
� Possibilities for commertial use of gypsumand requirements for gypsum quality
� Requirements for limestone quality and possible resources
"EUROGYPSUM SPECIFICATION"QUALITY STANDARDS
For the Product FGD Gypsum
QUALITY PARAMETERS FORMULA UNITQUALITY STANDARDS
Free moisture % by weight < 10
Calcium sulphate dihydrate CaSO4 x 2H2O % by weight > 95
Magnesium oxide water soluble MgO % by weight < 0,10
Sodium oxide Na2O % by weight < 0,06
Chloride CI % by weight < 0,01
Sulphur dioxide SO2 % by weight < 0,25
pH 5 - 9
Colour White
Odour Neutral
Toxicity Non-toxic
DESIGN LIMESTONE QUALITY REQUIREMENTS
Parameter Units Reporting Basis
Case 1, Disposable
Gypsum
Case 2,Wallboard Gypsum
Free Moisture Weight % As received �5,0 �5,0
Calcium Carbonate, Total as CaCO3
Weight % Dry �89,0 �94,0
Magnesium Carbonate, Weight % Dry �4,0 �,30Magnesium Carbonate, Total as MgCO3
Weight % Dry �4,0 �,30
Silicon Dioxide – as SiO2
Weight % Dry �5,0 �3,0
Iron Oxide – as Fe2O3 Weight % Dry ------ �0,8
Total Inerts (Including MgCO3)
Weight % Dry �,11,0 �6,0
Particle Size Analysis Millimeter Dry 19,05××××0 19,05××××0
Bond Work Index (BWI) KWh/T As received �10,8 �10,8
CHALLENGES AND OPPORTUNITIES FOR EP & SERBIAN INDUSTRY
� Consulting services in Project development� Participation in design of FGD subsystems, both
mechanical and electrical, such as♦♦♦♦ limestone handling and slurry preparation♦♦♦♦ gypsum slurry transport and disposal or
gypsum handlinggypsum handling♦♦♦♦ waste water treatment
� Civil design� Manufacturing of equipment, both mechanical
and electrical (except special parts and systems)� Execution of civil works� Assembling of mechanical and electrical
equipment (except special works on absorber)
THANK YOU FOR YOUR KIND ATTENTIONKIND ATTENTION