“steinmüller-tagung” 2013 23. – 24. april 2013
TRANSCRIPT
1Revamp and Retrofit of FGD Plants
“Steinmüller-Tagung” 2013 23. – 24. April 2013
Gummersbach, Germany
Titel / title:
Vortragender / presenter:
Revamp and Retrofit of FGD Plants
Dr. S. Binkowski
2Revamp and Retrofit of FGD Plants
Employment Record Dr.-Ing. Stefan Binkowski
since 02/13
Steinmüller Engineering GmbH, Gummersbach, Germany Department Manager Flue Gas Cleaning Process
2009- 2013
Steinmüller Engineering GmbH, Gummersbach, Germany Head of Flue Gas Desulphurization Department
2005- 2009
Steinmüller Engineering GmbH, Gummersbach, Germany Process Engineer Flue Gas Cleaning
2001- 2005
Lehrstuhl Umwelttechnik, Fachbereich Chemietechnik, Universität Dortmund, Germany, Dr.-Ing. (PhD)
2001 Graduation - Universität of Dortmund, Germany,Dipl.-Ing. (M.Sc. Chemical Engineering)
3Revamp and Retrofit of FGD Plants
Steinmüller Engineering FGD Portfolio
•
Consulting / Engineering
-
Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom)-
Training of Eskom FGD Engineers
•
Engineering / Optimisation / Supply-
Amsterdam Hemweg Optimization (Nuon)-
Owensboro Tray Revamp
(OMU)
•
Supply / New Built-
Paroseni RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)
4Revamp and Retrofit of FGD Plants
Steinmüller Engineering FGD Portfolio
•
Consulting / Engineering
-
Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom)-
Training of Eskom FGD Engineers
•
Engineering / Optimisation / Supply-
Amsterdam Hemweg Optimization (Nuon)-
Owensboro Tray Revamp
(OMU)
•
Supply / New Built-
Paroseni RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)
5Revamp and Retrofit of FGD Plants
Medupi 6 x 800 MW FGD Concept and Basic Engineering
Tutuka 6 x 600 MW
6Revamp and Retrofit of FGD Plants
Medupi 6 x 800 MW FGD Concept and Basic Engineering
7Revamp and Retrofit of FGD Plants
Medupi 6 x 800 MW FGD Concept and Basic Engineering
One of the largest FGD systems in the world,
2nd
in South Africa
8Revamp and Retrofit of FGD Plants
Medupi 6 x 800 MW FGD Concept and Basic Engineering
Steinmüller Engineering:•
Project Management Services•
FGD Process Design•
FGD Plant Design•
Special Studies (e.g. Material, Water Saving, Technology Evaluation, Reagents Specification)
•
Design Guidelines•
Development of Specifications•
Training Eskom Staff•
Skills Development•
…
Black and Veatch:•
Project Management
Services•
Civil Engineering•
Steel Structure Layout•
Bulk Material Handling•
Special Studies•
Life Cycle Cost Estimation•
Risk Assessment•
Grid (LV, HV)•
Enquiry Specification•
Schedule Development•
…
Eskom
9Revamp and Retrofit of FGD Plants
Steinmüller Engineering FGD Portfolio
•
Consulting / Engineering
-
Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom)-
Training of Eskom FGD Engineers
•
Engineering / Optimisation / Supply-
Amsterdam Hemweg Optimization (Nuon)-
Owensboro Tray Revamp
(OMU)
•
Supply / New Built-
Paroseni RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)
10Revamp and Retrofit of FGD Plants
FGD Engineering/Optimization
Different approaches possible, depending on project:
•
Optimizing gas flow distribution and gas-liquid contact-
Nozzle type-
Nozzle arrangement-
Wall rings- Tray-
CFD analysis
•
Optimizing FGD operation -
pH value-
Number of operated pumps-
Liquid level-
Limestone injection point-
Limestone quality
•
Combination of above mentioned measures
11Revamp and Retrofit of FGD Plants
Steinmüller Engineering FGD Portfolio
•
Consulting / Engineering-
Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom)-
Training of Eskom FGD Engineers
•
Engineering / Optimisation / Supply-
Amsterdam Hemweg Optimization (Nuon)-
Owensboro Tray Revamp
(OMU)
•
Supply / New Built-
Paroseni RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)
1212
FGD Engineering/Optimization – NUON Hemweg 8
680 MWbuilt by ESTS / HTS in 1994revamp by Steinmüller Engineering 2007scrubber diameter ~18 m
13Revamp and Retrofit of FGD Plants
Objectives
•
Increased removal efficiency without any increase in circulating flows or
additional installations by more than 2 %-points
•
Steinmüller Advanced Nozzle Positioning (ANP) uses customised spray bank layout and adapted
current technical state of the art nozzles and piping system
•
Implementation / Erection of new system
•
Further process optimizations
identified in additional study
FGD Engineering/Optimization – NUON Hemweg 8
14Revamp and Retrofit of FGD Plants
Optimizing gas flow distribution – ANP Advanced Nozzle Positioning
New, optimized spray banks
Better flowdistribution
15Revamp and Retrofit of FGD Plants
•
Effective use of secondary dispersion to increase surface for absorption and overall removal efficiency
Bright color of spray due to refraction indicates small droplets
Upper opening of tangential nozzle
Optimizing gas flow distribution – ANP Advanced Nozzle Positioning
16Revamp and Retrofit of FGD Plants
71 %
7.2 % Emission
92.8 % SO2 Removal
0
10
20
30
40
50
60
70
80
90
100
Effic
ienc
y [%
]Su
mp
Leve
l [m
]
0
100
200
300
400
500
600
700
800
Con
cent
ratio
n [p
pmv]
Load
[MW
]
Removal Efficiency [%]Sump Level [m]SO2 Inlet [ppm]SO2 Outlet [ppm]Total Load [MW]
89,84 %
22
0
10
20
30
40
50
60
70
80
90
100
Effic
ienc
y [%
]Su
mp
Leve
l [m
]
0
100
200
300
400
500
600
700
800
Con
cent
ratio
n [p
pmv]
Load
[MW
]
Removal Efficiency [%]Sump Level [m]SO2 Inlet [ppm]SO2 Outlet [ppm]Netto Load [MW]
92,78 %
22
Achieved efficiency improvement (3 of 4 levels in operation)
89.8 % SO2 Removal
10.2 % Emission
Increasing the FGD removal efficiency by 2.9 % points means reducing the SO2
emissions by nearly 30 %
71 %
29 %
17Revamp and Retrofit of FGD Plants
≈
reduces auxiliary power (e.g. 0.38 MW x 7000 h/a x 55 €/MWh ≈
146 000 €/a)≈
increase usable coal range 0.6 % S → 0.9 % S≈
increase plant output for same SO2
cap
Efficiency vs. L/G
0
20
40
60
80
100
0 50.000L/G
80
85
90
95
100
20.000
+ 18.2 %
+ 2.9 %
Achieved efficiency improvement (3 levels)
2.9 % of increased efficiency by spray bank layout equals an L/G increase of 18.2 % (~380 kW) !
18Revamp and Retrofit of FGD Plants
• Gas flow further homogenized• Absorbens guided from wall back into scrubber • Local increase of velocity and L/G
Efficiency improvement by 0.5 -
0.8 %-points
Optimizing gas flow distribution – Potential of wall ring installation
19Revamp and Retrofit of FGD Plants
Increasing sump level will increase total L/G Removal efficiency increased by 2.1 %-points
Optimizing FGD operation – Absorber liquid level vs. Number of pumps
20Revamp and Retrofit of FGD Plants
Steinmüller Engineering FGD Portfolio
•
Consulting / Engineering
-
Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom)-
Training of Eskom FGD Engineers
•
Engineering / Optimisation / Supply-
Amsterdam Hemweg Optimization (Nuon)-
Owensboro Tray Revamp
(OMU)
•
Supply / New Built-
Paroseni RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)
21Revamp and Retrofit of FGD Plants
Dual Flow Tray Tower
Perforated Plate EndsBent Up For Bolted
Connections
Perforated PlatesEquidistant Hole
Center Lines
Dual Flow Tray
Design
SESS WFGD Technology - Dual Flow Tray Absorber
22Revamp and Retrofit of FGD Plants
Acid Gas Control - WFGD
• Maximize mass transfer (e.g. SO3
, dust)• Shorter absorber design• 15 -
20 % lower Liquid/Gas ratio• Access/Maintenance support grid
Dual Flow Trays
• Lower outlet emissions possible•
Scale-free operation at IPL Petersburg w/multiple trays since 1983
23Revamp and Retrofit of FGD Plants
Owensboro Municipal Utilities - Elmer Smith Station Units 1 & 2
Owensboro Municipal UtilitiesElmer Smith Generating StationUnits 1 and 2Owensboro, Kentucky
• Wet FGD System 1994 Startup
• Open Spray Tower Absorbers
• 2007 Upgrade w/ Dual Flow Trays
• HaRDE®
Precipitators
• 151 MW / 290 MW
24Revamp and Retrofit of FGD Plants
Owensboro Municipal Utilities - Elmer Smith Station Units 1 & 2
Open Tower
DFT Tower
Startup
1995
Retrofit 2007Number of Trays
None
OneGas Flow (Am3/h)
3,167,375
3,167,375Inlet SO2
(ppmv)
2,000
2,000Outlet SO2
(ppmv)
80
40SO2
Removal
96 %
> 98 %Pressure Drop Increase (mbar)
< 5
No other changes to operating system components or chemistry
25Revamp and Retrofit of FGD Plants
•
Flue gas desulphurisation system for unit no. 4 of 150 MWel and hot water boiler of 103,2 Gcal/h
Paroseni Absorber Retrofit
26Revamp and Retrofit of FGD Plants
Steinmüller Engineering FGD Portfolio
•
Consulting / Engineering
-
Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom)-
Training of Eskom FGD Engineers
•
Engineering / Optimisation / Supply-
Amsterdam Hemweg Optimization (Nuon)-
Owensboro Tray Revamp
(OMU)
•
Supply / New Built-
Paroseni RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)
27Revamp and Retrofit of FGD Plants
Paroseni Absorber Retrofit – Design Parameter
•
Flue gas desulphurisation system for unit no. 4 of 150 MWel and Hot Water Boiler of 103,2 Gcal/h
28Revamp and Retrofit of FGD Plants
Paroseni Absorber Retrofit – Steinmüller Scope
Supply of:• Spray banks • Recirculation pumps• Agitators• Oxidation air blowers• Mist eliminators• Emergency quench
Process engineering for the wet FGD process
29Revamp and Retrofit of FGD Plants
Steinmüller Engineering FGD Portfolio
•
Consulting / Engineering
-
Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom)-
Training of Eskom FGD Engineers
•
Engineering / Optimisation / Supply-
Amsterdam Hemweg Optimization (Nuon)-
Owensboro Tray Revamp
(OMU)
•
Supply / New Built-
Paroseni RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)
30Revamp and Retrofit of FGD Plants
Steinmüller Engineering provides
•
experienced consulting
•
proven optimization concepts
•
customized engineering solutions
for your FGD.
Thank you!