Desulphurisation of South African Coal Using Low Power Micro
Thermal Power Generation - Fit for Future With Modern Desulphurisation Systems
Transcript of 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
3Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
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
4Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
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
5Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
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
6Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
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
� 6 GWe total capacity
� Maximum absorber size: 700 MWe
Dry Circulating Fluidised Bed (CFB) FGD
� 86 absorbers installed (14 absorbers in China)
� 14 GWe total capacity
� Maximum absorber size: 350 MWe
7Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
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
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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
9Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
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
10Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
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
11Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
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
12Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
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
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Wet Lime / Limestone FGD Technology
Basic Flow Sheet
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Wet Lime / Limestone FGD Process
Overall Reaction
SO2(g) + CaCO3 + 2H2O + ½O2 CaSO4*2H2O + CO2(g)
product: gypsum
oxi-air
additive: limestonesuspension
flue gas
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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
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Wet Lime / Limestone FGD – Spray Tower Design
Mist Eliminators
Spraying Zone
Sump equipped with Impulse Suspending System
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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
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Wet Lime / Limestone FGD - Typical Arrangement
� Clean gas to cooling tower
� No bypass
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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
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CFB FGD Technology
Basic Flow Sheet
21Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
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
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CFB FGD General Arrangement
CFB Absorber
Absorbent Silo
Fabric Filter
Clean Gas Duct
Raw Gas Duct
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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
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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
25Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
Boilers
Dust
StackDedusting(CFB)
ID-Fan(CFB)
Dedusting ID-Fan
Product
CFBAbsorber
CFB-FGD-Unit
Clean Gas
Retrofit of CFB FGD
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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
27Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
Modern Desulphurisation Technologies
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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
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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
30Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
Rugeley - 2 x 500 MWeCoal fired – FGD Retrofit
Selected Retrofit References
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Selected Retrofit References
Moneypoint - 3 x 305 MWeCoal fired – SCR and FGD Retrofit
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SCR ArrangementPrinciple
Selected Retrofit References
Moneypoint - 3 x 305 MWeCoal fired – SCR and FGD Retrofit
33Doosan LentjesThermal Power Generation – Fit for Future with Modern FGD Technologies
Selected Retrofit References
Moneypoint - 3 x 305 MWeCoal fired – SCR and FGD Retrofit
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