Part-financed by the European Union (European Regional Development Fund
Electron beam for NOx/SOx reduction at power plants
Andrzej Pawelec
Institute of Nuclear Chemistry and Technology, Warsaw, Poland
Poznań, 08.10.2013
Emission structure in Poland in 2009 as typical emission structure in Baltic Sea Region
52,14
19,21
28,04
0,38 0,21 0,01
33,19
11,9510,56
0,76
43,26
0,28
0,00
10,00
20,00
30,00
40,00
50,00
60,00
Energy generation Combustion processes
in industry
Non industrial
combustion processes
Industrial processes
except combustion
Transport Waste management
SO2
NOx
[%]
The following combustion processes may be a subject of EBFGT
application:
● Energy and heat generation
● Oil refineries
● Waste incinerators (municipal and medical)
● Cement and concrete production
● Metal production (ore sintering)
● And others.
Potential processes suitable for application of
electron beam flue gas treatment technology
Basis of electron beam flue gas
treatment technology
Some history
• Early phase (Japan, 1970s)
• Pilot plants phase (Japan, USA, Germany, Poland 1980s,
1990s)
• Industrial plants phase (China, Poland, late 90s)
• Recent attempts (China, Bulgaria, Middle East)
Present operating plant:
• EBFGT at Pomorzany Power Station, Poland
• New facilities under construction
Conventional flue gas treatment process vs. Electron Beam Flue Gas Treatment
Limestone-Gypsum Process (SO2 removal)
Ammonia Selective Catalytic Reduction Process (NOx removal)
Electron Beam Flue Gas
Treatment Process
EBFGT process course
Plasma generation by
electron beam irradiation
Pollutants removed by EB method
The method has been designed for simultaneous removal of:
• SO2
• NOx
Also there proceeds removal of other pollutants as:
• HCl, HF etc.
• Volatile Organic Hydrocarbons (VOC)
• Dioxins
• Others…
Advantages of EBFGT technology
• Simultaneous removal of SO2 and NOx,
multi-pollution control system
• High removal efficiency
• High flexibility of installation
• Dry process
• Wasteless process, usable by-product
• Simple facility construction
• Easy retrofitting
Industrial demonstrational flue gas treatment plant
EPS Pomorzany, Poland
EPS Pomorzany – general view
Main operational data
• Flue gas flow rate 100 000 - 270 000 Nm3/h
• Pollutants removal efficiency:
95 % SO2
70 % NOx
• Total accelerators power: 1.04 MW
• Inlet flue gas parameters:
temperature 130 – 150°C
SO2 concentration 1500 – 2200 mg/Nm3
NOx concentration 400 – 600 mg/Nm3
• Ammonia water consumption: 150 – 300 kg/h
• By-product yield: 200 – 300 kg/h
The scheme of industrial installation
EPS Pomorzany gas
cooling tower
Dry bottom spray cooler
adjusts temperature and
humidity to optimal
values for the process
EPS Pomorzany –
ammonia water tank
Ammonia is stored in the form
of 25% ammonia solution in
water. After evaporation
gaseous ammonia is injected to
flue gas ducts upstream the
reaction chamber. Ammonia
water can be also sprayed
straight to cooling tower.
EPS Pomorzany –
process vessel
Proper design of reaction
chamber results in high
efficiency of pollutants
removal
The obtained results
0
200
400
600
800
1000
1200
1400
1600
1800
30,00 40,00 50,00 60,00 70,00 80,00 90,00 100,00
Ammonia stoichiometry [%]
Re
mo
va
l [m
g/N
m3]
SO2
NOx
0
10
20
30
40
50
60
70
80
90
100
0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00
Ammonia mass fraction sprayed into cooling tower
Re
mo
va
l [%
]
0
10
20
30
40
50
60
70
80
90
100
5,0 5,5 6,0 6,5 7,0 7,5 8,0 8,5 9,0 9,5 10,0
Dose [kGy]
Re
mo
va
l [%
]
SO2
NOx
The results of industrial plant operation proved the applicability of
the technology to treatment of industrial flue gases
NPK fertilizers made of
by-product
Whole amount of by-product
is used for production of high
quality fertilizers
By-product composition:
(NH4)2SO4 45-60%
NH4NO3 22 - 30%
NH4Cl 10 - 20%
moisture 0,4 - 1%
water insoluble parts 0,5 - 2%
Future of electron beam flue gas
tretment technology
EBFGT facility in TPS Sviloza, Bulgaria
(design phase)
Plant
visualization
EBFGT facility in TPS Sviloza, Bulgaria
(design data)
Parameter Value
Volumetric flow rate
(Nm3/h, wet base, real oxygen
concentration)
608,000 Nm3/h (max)
488,000 Nm3/h (nominal)
Inlet flue gas parameters
Temperature
Flue gas composition:
140°C
N2 75.75%
O2 9.95%
CO2 8.3%
H2O 6.0%
Inlet pollutants concentrations
(6% O2, dry gas)
SO2
NOx
Dust
3800 mg/Nm3 (1330 ppmv)
1400 mg/Nm3 (682 ppmv)
400 mg/Nm3
Required removal rates:
SO2 72%
NOx 57%
EBFGT facility in TPS Sviloza, Bulgaria
(design phase)
Conceptual
scheme of
EBFGT plant in
TPP Sviloza
(Bulgaria)
EBFGT technology application for liquid fuels – laboratory tests
Sample results obtained during
laboratory research
Laboratory intalation at
INCT, Warsaw
EBFGT technology application for liquid fuels – pilot plant tests
General view of the pilot plant at Jeddah Refinery.
1. stack of F 1001 boiler, 2. boiler F 1001, 3. flue gas duct, 4. control room
of pilot plant, 5. humidification unit, 6. stack of pilot plant, 7. cartridge bag
filter, 8. thermal insulated duct, 9. cyclone, 10. ammonia dosing unit, 11.
mobile accelerator unit.
EBFGT technology application for liquid fuels – results
of pilot plant tests
SO2 and NOx removal efficiency
dependences.
EBFGT technology application for liquid fuels – the byproduct
Method of collection Bag filter ESP
Contents, % wt.
H2O 2.06 1.98
insoluble 1.40 4.04
Contents of anions and cations in the soluble fraction, % wt.
Cl- 0.0037 0.0365
NO3- 0.38 0.56
SO42- 79.02 65.79
NH4+ 20.48 33.49
Na+ 0.099 0.097
Mg2+ 0.0035 -
Ca2+ 0.017 0.019
Samples of obtained byproduct.
Byproduct composition
As Cd Cr Co Pb Hg Ni Zn Remarks
<0.02 <0.01 0.43 0.03 1.01 <0.03 63.5 18.3 averaged values for byproducts collected by cartridge bag filter
0.24 0.09 1.61 0.03 0.54 1.41 22.80 1476 byproducts collected by ESP
Limits for heavy metals content in NPK fertilizer
41 39 300 17 420 2800 US EPA CFR40 Part. 503
75 20 150 500 5 180 1350 Canadian Fertilizer Act (1996)
50 50 140 2 Polish standard
32.2 276.8 12.9 17.8 72.3 mean values in fertilizers marketed in the Kingdom of Saudi Arabia
Heavy metals content
EBFGT technology application for liquid fuels – possible implementation
Conceptual scheme of 160 000 Nm3/h capacity demonstration plant
EBFGT technology upscalling
ELV 12 accelerator, EB-Tech, Republic of Korea
• A 1 000 000 Nm3/h
capacity unit is
concerned
• High power accelerators
are developed
• Costs lowering is
obtained
Thank You for Your Attention
Andrzej Pawelec Ph.D.
Institute of Nuclear Chemistry
and Technology
Dorodna 16
03-195 Warsaw, POLAND
e-mail: [email protected]
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