Thermal Power Generation - Fit for Future With Modern Desulphurisation Systems

Thermal Power Generation

Fit for Future with Modern Desulphurisation Systems

Doosan Lentjes GmbH

Frank Oberheid - D-PM110.10.2012

2Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies

Content

� Company Introduction and History

� Pollutants in Focus

� Emission Limits

� Economical Aspects of Retrofit

� Desulphurisation Technologies

– Wet Lime/Limestone FGD

– Dry CFB FGD

– Comparison

� Selected Retrofit References


Products and Services

Doosan Power SystemsCEO JM Aubertin

Turnover 2011: £800mEmployees: 5,800

Doosan BabcockDoosan Lentjes Skoda Power Doosan Babcock

Boiler & Air Pollution Control Turbogenerators Plant Service

Doosan Heavy Industries


2011

Heritage

Acquired by Doosan Power Systems and renamed Doosan Lentjes

Doosan Power Systems is formedbringing Skoda and Babcock together

Acquired by Doosan

Acquired by Doosan to become Doosan Babcock Energy

Lentjes GmbH formed

Company becomes Skoda Power

Skoda Energoformed

Skoda daughter companies privatised

Babcock Power Ltd formed

Ferdinand Lentjes founds boiler manufacturing company

Babcock & Wilcox established

Engineering workshop founded

Babcock

Škoda Power

Lentjes

20051928

2004199819931859

200619791891 2009

2009


CFB

Circulating

Fluidised

Bed

APC

Air

Pollution

Control

EfW

Energy

from

Waste

� Top tier level CFB OEM technology

� References : 112 units (15 GW, max. 280 MWe)

� Various FGD portfolio OEM technology

� References :

– Wet FGD : 205 units (71 GW, max. 1,000 MWe)

– Seawater FGD : 10 units (6 GW, max. 700 MWe)– CFB FGD : 74 units (14 GW, max. 350 MWe)

� Top tier EfW OEM technology

� References : 75 lines (9 mill ton/yr, max. 40 ton/hr)� Chute-to-stack or full turnkey supply solutions

Doosan Lentjes is the global center of excellence

for engineering, procurement and construction

for CFB, APC and EfW:

Who is Doosan Lentjes?

Tisova, 100MWeCzech Republic

REC Harlingen, NL, 230.000 t/a; 1 line

Oroszlany, Hungary240MWe Wet Stack


Doosan Lentjes APC Products - Desulphurisation

Rugeley, UK, 2 x 500 MW

Paiton, Indonesia, 2 x 660 MW

Yushe, China, 2 x 350 MW

Wet Lime / Limestone FGD � 205 absorbers installed (110 absorbers in China)

� 71 GWe total capacity

� Maximum Size: 1,000 MWe

Seawater FGD� 10 absorbers installed


� Maximum absorber size: 700 MWe

Dry Circulating Fluidised Bed (CFB) FGD

� 86 absorbers installed (14 absorbers in China)


� Maximum absorber size: 350 MWe


Gottfried Bischoff GmbH & Co. KG

Gottfried Bischoff GmbH & Co. KG

Lentjes Bischoff GmbH

Lurgi Lentjes Bischoff GmbH

Lurgi Energie und Entsorgung GmbH

1910 - Foundation

1996

1998

2002

2004

Lurgi Lentjes AG

Lentjes GmbH

Doosan Lentjes GmbH

2004

2011 – Acquisition by Doosan Power System

1984 - Acquisition by Lentjes

2007AE&E Lentjes GmbH

FGD Technology - Origin


SOx� Acid Rain

� Forest Decline

� Support of Cloud Formation

NOx� Green House Gas

� Ozone Formation, Smog

Particles� Respiratory Disease

� Depending on Components also Cancer Disease

All: Negative Impact on Human Beings, Agriculture and Building Structures

Pollutant in Focus


Emission Limits

German Emission Limits – 13. BImSchV 2004for Coal-fired Power Plants > 100 MW thermal Power:

� SOx : max. 200 mg/Nm³, @ 6% O2

� NOx : max. 200 mg/Nm³, @ 6% O2

� Particles: max. 20 mg/Nm³, @ 6% O2

Regulation for Existing Power Plants:� Limits in general valid since: Due Date 01.11.2007

� Existing plants retrofitted in connection with former regulation13. BImSchV - 1983: Due Date 01.01.2011

Regulation applicable in Serbia – IED 2010/75/EU for Coal-fired Power Plants > 100 MW – 300 MW / > 300 MW thermal Power:

� SOx : max. 250 / 200 mg/Nm³, @ 6% O2

� NOx : max. 250 / 200 mg/Nm³, @ 6% O2

� Particles: max. 25 / 20 mg/Nm³, @ 6% O2

applicable for Operation after 1.1.2016


About 50% of WLSTAbout 50% of WLSTSCR

About 50% of WLST70-80% of WLSTDesulphurisation

SWFGD

At least 15 % higher

than WLST(disposal costs !!!)

70-80% of WLSTDesulphurisation

Dry (e.g. CFB FGD)

0.3 and more, (sulphur content !!!)

150 - 250Desulphurisation WLST

IndicativeOperating Costs

€ Cent/kWh

Indicative total Investment Costs

€/kW

Technology

Estimations based on EPRI, EPA, S&L, Mc Ilvain publications and own experience. Cost may vary significantly!

Estimated Costs for Clean Environment


FGD Technology for Retrofit in Europe

SeawaterFGD

AmmoniaWellmann LordFGD

Dry FGD(Spray Dry, CFB process)

Wet LimestoneFGD

• for coastal site only • complicated operation• very high investment• no new plants in recent years

• small market demandsfor fertiliser inthe moment

• Most important alternatives for inland retrofits in Europe


Specific Conditions important for Selection� Fuel

– Heating Value

– Sulphur Content

– Water Content

� Site Conditions

– Soil Conditions, Earthquake Class

– Space / Layout

– Infrastructure

– Climate

� Plant Configuration

– Availability

– Livetime

� Local Prices/Costs

– Reagent, Water

– Landfill

– Labour and Material

– Standards

Selection of Most Economic FGD Technogy


Wet Lime / Limestone FGD Technology

Basic Flow Sheet


Wet Lime / Limestone FGD Process

Overall Reaction

SO2(g) + CaCO3 + 2H2O + ½O2 CaSO4*2H2O + CO2(g)

product: gypsum

oxi-air

additive: limestonesuspension

flue gas


Wet Lime / Limestone FGD

Gypsum for the building industry

Gypsum wallboards

Plaster gypsum

Solidification agent for cement

Cement for the mining industry

Flooring

Gypsum chip boards

Gypsum fibre boards

Filler

Landscaping industry

Re-cultivation

FGDGYPSUM


Wet Lime / Limestone FGD – Spray Tower Design

Mist Eliminators

Spraying Zone

Sump equipped with Impulse Suspending System


Wet Lime / Limestone FGD Sump Design

� Suspends the solids without moving

parts within the absorber

� Better utilisation of consumables

� Higher quality of gypsum

� No need to operate Impulse Suspending System during shut-down

� Trouble-free restart of IS-System afterFGD shut-down

Special Advantages

only available with

Doosan Lentjes Sump System


Wet Lime / Limestone FGD - Typical Arrangement

� Clean gas to cooling tower

� No bypass


Wet Lime / Limestone FGD - Advantages

� New-built and retrofit

� Size: Up to 1000 MWe and even more

� Fuel: Coal, lignite, heavy fuel oil

� Suitable for high sulphur application

� SO2 Removal efficiency up to 99%

� High flexibility with regard to boiler load

� High number of references world wide

� Low absorbent cost, good utilisation(stoichiometric factor)

� “Saleable” product


CFB FGD Technology

Basic Flow Sheet


CFB FGD Process

Main reactions, significant for the flue gas desulphurisation in the fluidised bed

Ca(OH)2 + SO2 CaSO3 * 1/2 H2O + 1/2 H2O

2 CaSO3 * 1/2 H2O + O2 2 CaSO4 * 1/2 H2O

Ca(OH)2 + SO3 CaSO4 * 1/2 H2O + 1/2 H2O

CaO hydrated in a dry hydrating plant on site

CaO + H2O Ca(OH)2


CFB FGD General Arrangement

CFB Absorber

Absorbent Silo

Fabric Filter

Clean Gas Duct

Raw Gas Duct


Fabric Filter downstream CFB FGD

Advantages

� Far less than 10 mg/m³

� Independent from Boiler Load

� DeSOx-effect in ash layer on filter bag

� Furnace Sorption Injection or CFB

installation possible

� Relatively low Investment Cost

� Higher Life Time of Filter Bags


ID-Fan(Boiler)

ID-Fan

(Boiler)

ID-Fan(Boiler+CFB)

ID-Fan

(Boiler+CFB)

Boiler Boiler

Boiler

Boiler

Dedusting

(Boiler)

Dedusting(Boiler)

Dedusting

(Boiler+CFB)

Dedusting(Boiler+CFB)

Dedusting

(CFB)

ID-Fan

(CFB)

CFB Absorber

CFB AbsorberCFB Absorber

Existing Power Plant

Retrofit Variant CRetrofit Variant B

Retrofit Variant A

Dust ProductDust

Product

incl. Dust

Product

incl. Dust

Retrofit Alternatives for CFB FGD


Boilers

Dust

StackDedusting(CFB)

ID-Fan(CFB)

Dedusting ID-Fan

Product

CFBAbsorber

CFB-FGD-Unit

Clean Gas

Retrofit of CFB FGD


CFB FGD Process - Advantages

� Moderate process water consumption

� Small power consumption

� Small foot print

� No waste water – dry particles only

� High SO3 removal

� No flue gas re-heating

� Absorber made of carbon steel

� Easy adoption to higher SOx removal

� Attractive investment costs


Modern Desulphurisation Technologies


Plant configuration Booster fans, GGH, bypass, existing Stack, LS Mill, LSsupply system, gypsum

dewatering, WWT

Wet limestone

Booster fan, adsorber,low pressure pulse jet filter,bypass, existing stack, lime hydration and supply plant

CFB

Space requirements ca. 3,300 m² ca. 2,100 m²

Number of I/Os ca. 3,500 ca. 1,350

Pressure loss

Power consumption ca. 5.3 MWh/h ca. 3.5 MWh/h

Reagent consumption ca. 4.7 t/h limestone (90%) ca. 2.9 burnt lime (85%)

Process water consumption ca. 50…60 m³/h ca. 40…50 m³/h

ca. 20…30 mbar ca. 35…40 mbar

By-product production ca. 5.8 t/h gypsum ca. 5.7 t/h dry product

Amount of waste water ca. 12 m³/h none

Amount of sludge from WWT ca. 0.3 t/h none

Material selection Absorber: CS rubber lined orcladded / plated with alloy steel

Adsorber: CS

Comparison of WLST and CFB FGD

Project: 300 MW, Hard Coal, 1.2% S, 90%

Removal Efficiency


Oroszlany - 240 MWe lignite fired – Wet Stack Design

Guaranteed Emission Data

SOx < 400 mg/m³ (STP dry)

SOx Removal Efficiency > 97 %

HCl< 20 mg/m³ (STP dry)

HF< 5 mg/m³ (STP dry)

Particles< 30 mg/m³ (STP dry)

Droplets< 100 mg/m³ (STP dry)

Design Data

Gas Flow 1,140,000 m³/h STP, wet

SOx Inlet 14,000 mg/m³ (STP dry)

HCl Inlet 50 mg/m³ (STP dry)

HF Inlet 20 mg/m³ (STP dry)

Dust Inlet < 100 mg/m³ (STP dry)

Selected Retrofit References


Rugeley - 2 x 500 MWeCoal fired – FGD Retrofit




Moneypoint - 3 x 305 MWeCoal fired – SCR and FGD Retrofit


SCR ArrangementPrinciple






Contact Person:Frank Oberheid

Daniel-Goldbach-Straße 19

D-40880 Ratingen

Tel.: +49 2102 166 1484

Fax: +49 2102 166 [email protected]

www.doosanlentjes.com

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Thermal Power Generation - Fit for Future With Modern Desulphurisation Systems

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