alstom nid präsentation
TRANSCRIPT
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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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High Performance DFGD - 13/04/2007 - P 2
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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High Performance DFGD - 13/04/2007 - P 3
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.
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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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.
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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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.
Spray Dry Absorption
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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.
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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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.
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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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.
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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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.
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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High Performance DFGD - 13/04/2007 - P 11
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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High Performance DFGD - 13/04/2007 - P 12
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.
NID - Novel Integrated Desulphurisation
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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.
NID - Novel Integrated Desulphurisation
Uskmouth Power,
Unit 13, 14 & 15, 3 x 120
MWe
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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.
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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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.
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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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.
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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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.
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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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.
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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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.
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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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.
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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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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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.
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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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.
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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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.
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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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
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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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
NID - Novel Integrated Desulphurisation
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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.
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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