+ All Categories
Home > Documents > DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl...

DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl...

Date post: 25-Jul-2020
Category:
Upload: others
View: 17 times
Download: 2 times
Share this document with a friend
56
DFGD Process Equipment John Buschmann July 13, 2008 July 13, 2008
Transcript
Page 1: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

DFGD Process Equipment

John BuschmannJuly 13, 2008July 13, 2008

Page 2: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

2

System Design

Page 3: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

3

Typical DFGD Installation

Wet Flue GasDesulfurization

(WFGD)PulverizedCoal Boiler

SelectiveCatalyticReduction (SCR)

Spray Dryer Absorber (SDA)

Fabric Filter (FF)

Low NOxBurners

Air Preheater

Induced Draft Fans

Stack

Page 4: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

4

Typical DFGD Installation

Page 5: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

5

Typical DFGD Installation

Page 6: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

6

DFGD Process Flow Lime Only

Spray Dryer

Fabric Filter I.D. Fan

Slaker

StorageTank

B

B

Lime

Water

WaterFlue Gas

Disposal

Page 7: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

7

DFGD Process Flow Recycle

Spray Dryer

Fabric Filter I.D. Fan

Slaker

FeedTank

StorageTank

B

B

Lime

Water

Recycle Silo

Water

Disposal

Flue Gas

Disposal

Page 8: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

8

SDA Spray Cloud

Page 9: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

9

Atomizing Key to the Process

• Fine Droplet Size• Uniform Size

Distribution

• Controlled Cloud Shape

• Optimum Gas/Liquid Mixing

• Stable and ControlledTemperatures

Page 10: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

10

Rotary Atomizer

• Inlet Gas Distributor and Atomizer– Disk Rotates 8,000

to 13,000 rpm

– <50 Micron DropletsCreated by Centrifugaland Shear Forces

– Each Atomizer Unit Operates Independently

ATOMIZERMOTOR

SPINNINGDISK

TURNINGVANES

GASFLOW

Page 11: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

11

Rotary Atomizer –CFD Model

Page 12: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

12

Reactor Design

Slurry drying and acid gas scrubbing

10 to 15 seconds gas retention time Reactors from 3 ft to 69 ft diameter Single or multiple atomizers Can be designed with an installed

spare atomizer Physical and CFD models

Page 13: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

13

Temperature Control

Dry Bulb Temperature

Wet Bulb Temperature

Approach Temperature

Page 14: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

14

Psychrometric Chart

30 °F Approach to Saturation Temperature

~43% Relative Humidity

Inlet Flue Gas Moisture

30 °F dT

Inlet Flue Gas Dry Bulb Temperature

Adiabatic Saturation Temperature (AST)

Dew Point Temperature

Page 15: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

15

DFGD Reactions & Products

Lime Slaking

CaO + H2O Ca(OH)2(s)

Acid Gas Scrubbing

SO2 + Ca(OH)2 CaSO3-½H2O(s)+ ½H2O(g)

SO2 + Ca(OH)2 + H2O + ½O2 CaSO4-2H2O(s)

SO3 + Ca(OH)2 + H2O CaSO4-2H2O(s)

CO2 + Ca(OH)2 CaCO3(s) + H2O(g)

2HCl + Ca(OH)2 CaCl2-2H2O(s)

2HF + Ca(OH)2 CaF2(s) + 2H2O(g)

Page 16: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

16

System Components

Page 17: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

17

Reagent Preparation

Lime Slaking Accomplished by:– Detention– Paste– Milling– Slaking must take place at high temperature

Final Slurry Preparation Combines– Lime Slurry– Dilution Water (waste water)– Dry Recycle (optional)

Page 18: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

18

Lime Quality

a. Particle Size: 3/4” x 0” with no more than 50% less than 10 mesh.

b. Availability: 90 % CaO or greater as measured by ASTM Method C25.

c. Reactivity: Greater than 40 °C temperature rise at three minutes as measured by ASTM Method C110.

Page 19: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

19

Lime Slaking Guidelines

Slaking Temperature - 175°F +/-

Diluted to 20% solids

Filtered to 20 mesh or less

Settled Volume after 24 hrs >50 ml @ 10% solids

Page 20: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

20

Paste Slaker

Page 21: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

21

Detention Slaker

Page 22: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

22

Vertical Mill Slaker

Page 23: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

23

Reagent Preparation Area

Page 24: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

24

Lime Slaking and Storage

Page 25: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

25

Alstom SDA

Page 26: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

26

Flue Gas Inlet Ducts

Page 27: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

27

B&W SDA

Page 28: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

28

Gas Disperser

Page 29: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

29

Multiple Atomizers

• Each Atomizer Acts Independently

• Excellent Interface Between Flue Gas and Lime Spray for SO2 Collection

• Three atomizers per SDA• Optional operation with two out

of 3 atomizers at full load• Turndown to 10% load

• Designed for 12 Second

Retention Time

Page 30: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

30

Rotary Atomizer

Page 31: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

31

Rotary Atomizer Assembly

• Each has up to 150 MW flue gas scrubbing capacity

• 450 MW Capacity Spray Dryer with 3 Atomizers

• Assembly Can Be Hoisted Up While the Spray Dryer is in Operation

• Proven Reliable Design30 years of power plant service

• Over 150 Rotary Atomizersin Operation

Motor

FlexShaft

Gearbox

AtomizerWheel

Page 32: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

32

Rotary Atomizer Assembly

US manufactured

150+ Machines in daily service

40 Locations

60 – 400 hp

8,000 to 15,000 rpm

Page 33: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

33

Rotary Atomizer

• Reliable Operation:• Vibration Monitors are

Standard• Sophisticated Lubrication

System with Filters and Coolers

• Careful Selection of Bearings and Gearbox Components

• Quick Removal from Spray Dryer Vessel for Inspection and Service

Page 34: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

34

Rotary Atomizer Disk

Shaft

Nozzle Slurry InWear Plates

DiskAtomizedSpray

Page 35: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

35

Fabric Filter as a Chemisorption Device

Applications:

• SO2 SO3 HCI HF Dioxin,

Mercury Removal

• Spray Dryer

• Dry Injection

• Lime, Sodium Bicarbonate,

Carbon

Atomizers

Fabric Filter

Stack

Flue GasInducedDraft Fan

Dry FGDReactor

Flyash forDisposal OrRecycle

SO2 and HCl Removal with Spray Dryer

Page 36: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

36

SO2

SO2

SO2

SO2

SO2

SO2

FABRIC FILTER

Important part of DFGDReaction

– Second Stage SO2 Removal

– Patented Process (No. 4,197,278)

Collection

– Fly ash– Reaction Products

Page 37: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

37

FF Compartment Plan View

Page 38: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

38

Rotary vs. Dual Fluid Atomization

Page 39: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

39

Dual Fluid Nozzle Atomization

• Air is Used toAtomize the Slurryto Fine Droplets

• Droplet Distribution20 to 60 Microns

• Abrasion ResistantNozzle Tips EnsureLong Life

Page 40: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

40

Dual Fluid Nozzle Gas Disperser

• Lime Slurry is Atomized by Compressed Air

• Individual Nozzles Can Be Removed While the Spray Dryer is On-Stream

• Spray Pattern is Tailored to the Spray Dryer VesselConfiguration

Page 41: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

41

Nozzle Spray Dryer Gas Inlet

• Flue Gas is Balanced and Directed to Individual Nozzle Assemblies

• Turning Vanes Ensure Equal Gas Distribution at the Nozzle Tips

Page 42: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

42

Nozzle Spray Dryer Gas Distribution

• Equal Gas Distribution at Each Nozzle Ensures Even Gas Distribution at the Reactor Bottom

• Multiple Nozzles Minimize Flue Gas “Bypass” Inside the Reactor

• Gas Flow Evens Out as the Gas Flows Downward Toward the Bottom Outlet

Gas and Slurry In

Page 43: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

43

Dual Fluid Nozzle Disadvantages

• Limited slurry flow rate per nozzle requires many nozzles and complex piping

• Each rotary atomizer has 10x larger capacity thus fewer are needed

• Air compressors are inefficient• Much of the energy in the compressed air is

wasted by the nozzle• Rotary atomizers are over 90% efficient

• Power savings can be over a MW

Page 44: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

44

Atomization design of Major suppliers of Dry FGD

Original Developers of DFGD in 1978 Joy / Niro - Rotary B&W - Nozzle Rockwell - Rotary CE - Both Carborundum - Nozzle Flakt - Nozzle

Consolidation over past 30 years B&W - Rotary Alstom - Rotary

Over 90% of all DFGD systems use Rotary Atomizer

Page 45: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

45

Spray Dryer Alternatives

Page 46: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

46

Flash Dryer Process Concept

• Very High Solids Recirculation

• No Slurry Handling

• “Dry” Product

• High Utilization of Reagent

TC ESP or Fabric Filter

Recirculation

Humidifier

Water

Reagent End Product

Page 47: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

47

Flash Dryer Absorber

• Modular design• Operations are closer to

grade• High Reliability• Approximately 1.2

seconds gas residence time

• No high pressure or high speed atomizers

• No slurry handling

Page 48: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

48

FDA Multiple Module System

• Each Mixer Acts Independently

• Excellent Interface Between Flue Gas and Humidified Recycle for SO2 Collection

• Continuous Recirculation with Air Slides and Fluidized Troughs

• Controlled Water to Recycle Ratio

• Dry Waste Product Calcium Sulfite/Sulfate

Page 49: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

49

FDA History

• Pilot Plant at Univ. of Tennessee – 1988

• Pilot Plant at TVA Shawnee – 1992

• European pilots – 1995

• Full Scale Laziska Retrofit - 1996

• Currently 62 installations - over 6000 MW

Page 50: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

50

FDA – Laziska Power Plant 2x125 MWe

Page 51: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

51

FDA / Fabric Filter (3 x 120 MWe)AES Fifoots Point PS, Wales, UK

Page 52: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

52

Reliant - Seward StationFlash Dryer Absorber (FDA)

Page 53: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

53

FDA + ESP 70 MW

Zhejiang # 8, PRC

Page 54: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

54

FDA/ESPJuhua Group / ZCE Boiler No. 8, Zhejiang, PRC

Page 55: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

55

• Low investment• Less Equipment

Spray dryerSlurry handling equipment less maintenance

• Reduced power consumption• Compact reactor design housed under the particle

collector• High SO2 removal efficiency

FDA – Advantages

Page 56: DFGD Process Equipment - WPCAwpca.info/pdf/presentations/APC_Savannah_July2008/DFGD...SO2 and HCl Removal with Spray Dryer 36 SO2 SO2 SO2 SO2 SO2 SO2 FABRIC FILTER Important part of

www.alstom.com


Recommended