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Worldwide Pollution

Control Association

ESKOM Scrubber Seminar

April 12th 13th, 2007

Visit our website at www.wpca.info

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POWER SYSTEMS

Lorentz Rivelius13/04/2007

High Performance DFGD

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ALSTOM 2007. We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Agenda

1st topic Introduction & History Page 1

2nd topic Process concept Page 11

3rd topic DFGD reaction & NID working principle Page 23

4th topic Comparison between technologies Page 33

5th topic Summary Page 37

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Introduction

DFGD - SDA (first DFGD technology) DFGD - NID (second generation DFGD)

SWFGD (sea water desulphurisation)

WFGD (wet flue gas desulphurisation)

ASFGD (ammonium based desulphurisation)

Other special technologies for example developed forpetrochemical and chemical industry

Several technologies are available for power plant flue

gas desulphurisation, for example:

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History in short

Late 70s - first requirement on small on medium sizepower plants i northern Europe to lower their SO2

emission Search for suitable technology started aim to find less

complicated system to operate

Basic understanding of chemistry and physics for drysystems established - Ca(OH)2 reacts with SO2 if thetemperature and humidity is right (not to saturation)

First systems used spray dryers, a known mechanicalcomponent, able to cool the gas and inject lime at thesame time.

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Spray Dry Absorption

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Spray Dry Absorption

South Carolina Electric &

Gas

Cope Unit 1, 385 MW

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History in short

Two main types of spray dryers developed

Nozzles using compressed air for injection

Rotary atomisers using a spinning disk Support systems in form of lime slaking and slurry

preparation

Removal of produced dust (CaSO3) with either fabricfilters or electrostatic precipitators

Systems developed both with and without pre-collector

for fly ash

Several hundred spray-dryer-based air pollution controlsystems have been installed at power plants, waste

incineration plants and industrial processes

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History lessons learnt

Wearing on the nozzles could influence the drop sizecausing:

deposits on the walls and sudden fall downs into thebottom corrosion on the spray dryer walls due to low temperature

behind the deposits

wet bottoms and difficulty to discharge fall-outs Clogging in the slurry pipes and tanks

Sometimes difficulty to inject sufficient amount of lime

and re-circulate dust due to small amount of waterneeded for cooling - result, limitation in performance andhigher than necessary operating costs

In the spray dryer there is a link between the cooling and theamount of solid material possible to inject due to limitations

in slurry density

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History ALSTOM development initiative

Aim:

a system without lime slurry

no link between cooling and amount of lime possible toinject

lower maintenance costs less complicated operation (forgiving in case of operator

faults)

ALSTOM development

Novel Integrated Desulphurisation (NID) developed1995.

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Introduction & history summary

First ALSTOM DFGD SDA-system started up in 1982 More than 140 dry systems installed by ALSTOM until

today

NID - a DFGD technology based on more than 25years of experience

First commercial NID installationoperated since 1996

Dry Desulphurisation (DFGD)

Laziska Power Plant,

Poland,

2 x 120 MW.

First NID installation

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ALSTOM 2007. We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Agenda

1st topic Introduction & History Page 1

2nd topic Process concept Page 11

3rd topic DFGD reaction & NID working principle Page 23

4th topic Comparison between technologies Page 33

5th topic Summary Page 37

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NID - Novel Integrated Desulphurisation

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NID - Novel Integrated Desulphurisation

Uskmouth Power,

Unit 13, 14 & 15, 3 x 120

MWe

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DFGD Basic Principles

Over all chemical reactionSO2 + CaO + H2O CaSO3xH2O

AbsorptionSO2 + Ca(OH)2 CaSO3xH2O + H2O

Hydration if the process start with CaOCaO + H2O(l) Ca(OH)2 + Heat [H2O(g)]

Reaction prerequisites for all DFGD systems if lime

utilisation shall be efficient: Reaction temperature low enough Relative humidity high enough Contact time and contact surface (area) sufficient

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NID Parameters

Flue Gas SO2 Content

Tested up to 3500 ppm Economics often limits application to max 1,5 - 2,0 % S in fuel

Flue Gas Inlet Temperature

Low temp preferred; max approx. 200C

Gas flow

Operating range from 40 000 Nm3/h to 1 200 000 Nm3/h

Acid mist SO3 removed approx. to the detection limit

Hydrogen halogens

HCl, HF removed by +90 %

Fine particulate matter efficiently collected by filtration and absorption

Mercury removal with minor addition in equipment

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SDA vs. NID Moist content in slurry & on dust

% H2O

70

Thin slurry60

50

40Thick slurry

30

20Paste

10

Free flowing dust

Wet/Dry Process NID Dry ProcessAdsorbed equi libriummoisture

5

NID

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NID features

Simple, robust & reliable

Proven technology

Internal slaking of the reagent

Less maintenance due to less equipment

No slurry handling

Small footprint - Integrated FGD and Fabric Filter saves space

High SO2 removal efficiency

Very low particulate emissions Low investment cost (compared to ESP + Wet FGD & SDA)

No pre collector required

3000 MW in operation

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NID - End Product Chemical Composition

Main components Typical range (%)

Fly ash/lime inert 3-10

CaSO3 40-70

CaSO4 5-15

Ca(OH)2 2-10

CaCO3 5-15

CaCl2 1-4

Moisture (free) 1-3

Besides these main components there will be a trace metal content in the endproduct, which is associated with the content of fly ash and the lime sources. Dueto the dense and alkaline nature of the dry FGD material it has a low leachability.

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NID - End Product Characteristics

Dry FGD product particle size

ca. 5 m to 60 m, with a mass mean size of 10 to 15 m.

Bulk density of dry product:

about 700 kg/m

3

Water solubility:

the total solubility of the dry FGD product in water is very

low. With exception for CaCl2 the different compounds aresparingly soluble to insoluble.

At ambient air conditions calcium sulphite (CaSO3) willslowly oxidize to calcium sulphate (gypsum) and calcium

hydroxide will be converted to CaCO3 by CO2.

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NID - End Product Utilisation

Civil works

Sealing material Base course material

Fill for landscaping / land reclamation

Fertilizer in agriculture and forestry Dry FGD product as Reagent for Wet FGD and Conversion to

Gypsum

Dry FGD product as raw material for aggregates, bricks and cement

Sand-lime bricks

Cellular concrete (autoclaved aerated concrete, gasbeton)

Cement (special cement process)

Aggregates/Synthetic gravel

ND End Product Utilisation

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ND End Product UtilisationProperties for End Product + Fly Ash

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DFGD - End Product Utilisation Examples

Picture on new harbour quay in

Vsters, Sweden

Storage area for wood chippings and coal on

Cefill base course at CHP Vsters, Sweden

Coal mine application in Poland (Photo: UTEX,

Rybnik)

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Agenda

1st topic Introduction & History Page 1

2nd topic Process concept Page 11

3rd topic DFGD reaction & NID working principle Page 23

4th topic Comparison between technologies Page 33

5th topic Summary Page 37

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NID Side view of NID FF

Gilbert Unit 3, CFB+NID

USA

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NID Layout

S C

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NID Standard Components

NID Mi / H d t

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NID Mixer / Hydrator

Recycle CaO

Recycle+Ca(OH)

2

Hydrator

MixerDispersion Plate(inside the Reactor)

H2O

NID Mi / H d t

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NID Mixer / Hydrator

Recirculation

rotary valve

Hydrator

Mixer

Reactor

NID H d t C t

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NID Hydrator Concept

Concept

Hydration in separate compartment integrated with theNID humidifier

CaO feed controlled directly, based on SO2 emission

Hydrate added to humidifier by displacement of CaOaddition; overflow directly into humidification section

Advantages No intermediate silo No separate filter; venting through NID FF No transport of hydrated lime; direct

overflow

NID R t

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NID Reactor

Entrained Flow

Reactor

Fabric Filter Bags and Support Cages

http://../Technical/NID/Presentation/Dfgd/!Nid-General/Baspresentation/Mixer%2001.mpg

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Fabric Filter Bags and Support Cages

Outside/ in filtration

low face velocity non-obstructed release of dust

cake

Filtration media options

various fabric material andtreatment

5-10 m bag lengths

Support cage options

adopted to selected fabricmaterial

whole or split design SPLIT BAG CAGE

NID Fabric Filter

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NID Fabric Filter

OPTIPOWOPTIPOW--ValveValve Venturi FlushingFlushing

Reduces re-deposition of fine dust

Cleaning the internal of the filter

mediaLow pressure (200 kPa)

Short and quick pulse (deep pulse)

Deep pulse = long bag capability

Modulated return of fil terModulated return of fil termediamedia

Soft return to operation

Reduces dust emission

Increase bag life

Agenda

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Agenda

1st topic Introduction & History Page 1

2nd topic Process concept Page 11

3rd topic DFGD reaction & NID working principle Page 23

4th topic Comparison between technologies Page 33

5th topic Summary Page 37

FGD technology indicators

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FGD technology indicators

Seawater Limestone DryPositiveIndicators

Near sea Low/medium sulphur Larger flue gas flow Long cost evaluation

period

Medium/high annualoperating hours

High sulphur Larger flue gas flow Gypsum market Medium/long cost

evaluation period

Medium/high annualoperating hours

Low/medium sulfur Small/medium flue

gas flow Short/medium cost

evaluation period

Low/medium annualoperating hours

NegativeIndicators

Effluent perceptionissues

Emerging economy Limited landfill area High lime/limestone

cost ratio

Low Medium High

Flue Gas Volume

Spray - DryLow

Medium

High

SulfurContent

Dry FGD

Wet Limestone

Seawater

Comparison DFGD - WFGD

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Comparison DFGD - WFGD

1 kg of Sulphur

5.2 kg of

DFGD end prod.

2 kg of SO2

2.6 kg of CaO

1 kg of Sulphur

5.1 kg of

gypsum

2 kg of SO2

3.2 kg of CaCO3

DFGD WFGD

Note, for illustration, approximate values only

DFGD comparison

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DFGD comparison

H2O

Lime milk

H2O

100%

50%

Investm

ent

SDA Large reactor Dust collector High energy

consumption inatomiser/nozzles

Lime slurry CaO

0%

CFB Small reactor Dust collector No lime slurry

Ca(OH)2 Water injection

into flue gasstream

NID (FDA) No reactor

Dust collector No lime slurry CaO No water injection

into flue gasstream

Agenda

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Agenda

1st topic Introduction & History Page 1

2nd topic Process concept Page 11

3rd topic DFGD reaction & NID working principle Page 23

4th topic Comparison between technologies Page 33

5th topic Summary Page 37

NID - Novel Integrated Desulphurisation

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NID Novel Integrated Desulphurisation

Proven technology

Simple, robust & reliable

Low capital investment cost

Internal slaking of the reagent

No slurry handling

Less equipment lessmaintenance

Integrated dust collector

Small footprint

NID Advantages

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NID Advantages

Process water flexibility

Uncomplicated operation

No waste water

Dry reagent and end product

Cleaned gas above saturation withoutreheat

Suitable up to 300 MW

No free droplets in the flue gas stream

Mai Liao, CFB+NID,

Formosa Heavy Industries, Taiwan

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