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Tanjung Jati B Units 3 & 4 660 MW Coal-Fired Project

Wet Limestone Flue Gas Desulfurization System

Dewatering System
operation & maintenance

Wuhan Kaidi Electric Power Environmental Co.,Ltd

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ABSORBER SYSTEM

Dewatering system process flow
Dewatering system equipment
Dewatering system startup & shutdown
Dewatering system control
Dewatering system trouble shooting

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PROCESS FLOW

Primary Dewatering - Gypsum Hydroclones
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PROCESS FLOW

Secondary Dewatering - Vacuum Belt Filter
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EQUIPMENT & DATE Gypsum Hydroclone 60m3/h. Two (2) cyclones per hydroclone (2 spare). PU or Carbon Steel with Rubber Lining 5 /61 EQUIPMENT & DATE Vacuum Belt Filter 6 /61 .

EQUIPMENT & DATE Vacuum belt filter Output Q=10. Q=15m3/h H=60m 8 /61 .5(h) Cloth wash tank pump centrifugal.ž1.3t/h.5m3. P=40kPa Cloth wash tank V=3m3 ¶1.5x1(h) Vacuum Pump Q=4400m3/h.5x1. Carbon Steel and Other Material 7 /61 EQUIPMENT & DATE Vacuum Receiver Effective Volume 1. Filter Area 12m2.

Q=15m3/hˈ H=40m(slurry head) 10 /61 .ž2x3(h) Gypsum Hydroclone Overflow Tank Pump centrifugal.5kw Chloride Purge Tank Pump centrifugal. Q=15m3/hˈ H=35m(slurry head) Gypsum Hydroclone Overflow Tank Agitator Carbon Steel with rubber Lining Shaft Power=2kw 9 /61 EQUIPMENT & DATE Waste Water Hydroclone 15m3/h.Cyclones 2+2(Spare) Chloride purge tank V=35m3.5(h) Chloride purge tank agitator Shaft Power=2. EQUIPMENT & DATE Gypsum Hydroclone Overflow Tank Effective Volume 8m3.ž4x3.

with no slurry attached to all cylinders. 2. Vacuum belt conveyor startup permits satisfied 11 /61 STARTUP & SHUTDOWN System startup sequence˖ 1: Start up vacuum belt filter wash pump A or B. STARTUP & SHUTDOWN Inspection before system startup 1. Common system operates normally. Gypsum slurry has proper amount of solids. 3. 4. with a delay time of 5s 5: Open vacuum belt filter gypsum slurry feed valve 12 /61 . with a delay time of 30s 2: Start up vacuum belt filter 3: Open vacuum belt filter vacuum pump seal water valve 4: Start up vacuum belt filter vacuum pump. The belt conveyor is clean.

Vacuum belt conveyor belt tracking . STARTUP & SHUTDOWN System shutdown sequence˖ 1: Close vacuum belt filter gypsum slurry feed valve.Filter cloth wash water .Vacuum pump .Hydroclone pressure differential 14 /61 . with a delay time of 10s 4: Shut down vacuum belt filter wash pump A and B 5: Close vacuum belt filter vacuum pump seal water valve 13 /61 CONTROL ALARMS: . with a delay time of 120s 3: Shut down vacuum belt filter. with a delay time of 120s 2: Shut down vacuum belt filter vacuum pump.

CONTROL Inspections: .Vacuum filter belt cleanliness .Leakage of slurry at hydroclones 15 /61 TROUBLE SHOOTING Gypsum dewatering is Poor.Vibration and temperatures .Slurry overflow in vacuum filter belt slurry distribution box . with much water content Slurry Cake Discharge at Vacuum Belt Filter 16 /61 .Circuit breaker status .

17 /61 TROUBLE SHOOTING Gypsum Hydroclone Slurry Leakage 18 /61 . TROUBLE SHOOTING Filter cloth wash water spray head is blocked.

TROUBLE SHOOTING Filter cloth displacement. 19 /61 .

Ltd 1 /61 ABSORBER SYSTEM Limestone slurry prep system process flow Limestone slurry prep system equipment Limestone slurry prep system startup & shutdown Limestone slurry prep system control Limestone slurry prep system trouble shooting 2 /61 . Tanjung Jati B Units 3 & 4 660 MW Coal-Fired Project Wet Limestone Flue Gas Desulfurization System Limestone Slurry Prep System operation & maintenance Wuhan Kaidi Electric Power Environmental Co..

PROCESS FLOW Wet Ball Mill System 3 /61 PROCESS FLOW Wet Ball Mill Lubrication System 4 .

PROCESS FLOW Absorber Area Sump 5 /61 EQUIPMENT & DATE Limestone Weigh Feeder 6 /61 .

EQUIPMENT & DATE Wet Ball Mill 7 /61 EQUIPMENT & DATE 8 /61 .

EQUIPMENT & DATE Weigh Feeder Q=0̚10t/h L=7m Wet Ball Mill Q=6.5t/h Carbon Steel and Rubber Lining Shaft power=200kw 9 /61 EQUIPMENT & DATE Wet Ball Mill Outlet Tank 10 /61 .

5(h).5x2(h) Mill Outlet Tank Agitator Mill Outlet Tank Pump Q=50m3/h H=30m(slurry head) Shaft power=15kw 11 /61 EQUIPMENT & DATE Reagent Slurry Storage Tank ž4x3. EQUIPMENT & DATE Mill Hydroclone Q=50m3/h Mill Outlet Tank Effective Volume 8m3.ž2.5kw 12 /61 .V=35m3 Reagent Slurry Storage Tank Agitator Shaft power=6kw Reagent slurry storage tank pump Q=40m3/h H=45m(slurry head) Shaft power=19.

5(h).V=140m3 Reagent Slurry Feed Tank Agitator Shaft power=3.7kw 14 /61 .4kw 13 /61 EQUIPMENT & DATE Limestone Prep Area Sump 4h4h3mˈV=40m3 Limestone Prep Area Sump Agitator Shaft power=3kw Limestone Prep Area Sump Pump Q=50m3/h H=20m(slurry head) Shaft power=6.5kw Reagent slurry Feed tank pump Q=50m3/h H=35m(slurry head) Shaft power=18. EQUIPMENT & DATE Limestone Slurry Feed Tank ž6x5.

Limestone silo level > minimum 5.5 m3/hour. 4: Start mill outlet tank pump A system or mill outlet tank pump B system 5: Warning light and warning horn will activate automatically prior to start of wet ball mill 6: Start wet ball mill 16 /61 . and close limestone slurry distributor product valve A 3: Open wet ball mill A water flow control valve. Limestone slurry feed tank level not high 15 /61 STARTUP & SHUTDOWN Wet Ball Mill Start-up Sequence 1: Start mill lube oil A system and mill lube oil B system 2: Open limestone slurry distributor backward valve A. and set water flow control set point to 2. Common system operating normally 4. STARTUP & SHUTDOWN Inspection before system startup 1. Lubrication oil system ready 2. Grease level is normal 3.

9uBMNF (Ball mill new feed). and set flow control dilution water on internal flow set value=9m3/h 8: Start limestone weight feeder 9: Set flow point of mill outlet tank water flow control valve on 1.45uBMNF (Ball mill new feed). wait until mill outlet tank pump A or B speed arrives at about 80% of inverter controlled speed range. and Set flow point of wet ball mill water flow control valve on 0. 17 /61 STARTUP & SHUTDOWN Wet Ball Mill Start-up Sequence 10: Close limestone slurry distributor backward valve A. and open limestone slurry distributor product valve A 11: Set mill outlet tank level control on automatic and set point o wait density value arrives to set density control with mill outlet tank water flow control valve on automation 18 /61 . and shutdown ball mill flashing light. and shutdown ball mill horn. STARTUP & SHUTDOWN Wet Ball Mill Start-up Sequence 7: Open mill outlet tank water flow control valve.

and close mill outlet tank water flow control valve to 0%.wait until density<22wt% low signal is activated (grind out time) 2: Close wet ball mill water flow control valve to 0%. and close limestone slurry distributor product valve A 5: Stop mill outlet tank pump A system or mill outlet tank pump B system 6: Stop mill lube oil pump A system and mill lube oil pump B system 20 /61 .5m3/h.and dilution water control to set point value 9m3/h. a delay time of 120 seconds 19 /61 STARTUP & SHUTDOWN System shutdown sequence˖ 4: Open limestone slurry distributor backward valve A. STARTUP & SHUTDOWN System shutdown sequence˖ 1: Stop limestone weight feeder.0 m (alarm)signal activated 3: Stop wet ball mill. and ball mill process water control to set point value 2.wait until mill outlet tank level < 1.

4: When both above flow control valve position < 1% and mill outlet tank level<1000mm.wait 120 seconds. stop mill outlet tank pump. and set grinding water control to internal set point 2. Open limestone slurry distributor backward valve A. 6: Shutdown mill lube oil pump A system and mill lube oil pump B system 22 /61 . STARTUP & SHUTDOWN System emergency shutdown sequence˖ 1: Stop wet ball mill 2: Stop limestone weight feeder.and set dilution water control to internal set point 9m3/h.5m3/h. wait 120 seconds. 3: Close wet ball mill water flow control valve to 0%. and mill outlet tank water flow control valve to 0%. and close limestone slurry distributor product valve A 21 /61 STARTUP & SHUTDOWN System emergency shutdown sequence˖ 5: If shutdown is expected to last longer than 30 minutes.

Ball mill outlet tank density 23 /61 CONTROL Wet Ball Mill System Alarms: . CONTROL Wet Ball Mill System Control: .Ball mill outlet tank level .Ball mill hydroclone 24 /61 .Ball mill & ball mill motor .Ball mill oil system .

Vibration & temperature .Circuit breaker status . CONTROL Ball Mill System Checks: .Water / slurry leakage .Ball mill outlet tank level / overflow 25 /61 TROUBLE SHOOTING Steel balls must be added periodically to maintain ball mill efficiency 26 /61 .

.Ltd 1 /61 FGD CHEMICAL SAMPLE & ANALYSIS Limestone sampling and analysis Limestone slurry sampling and analysis Absorber slurry sampling and analysis Gypsum sampling and analysis 2 /61 . Tanjung Jati B Units 3 & 4 660 MW Coal-Fired Project Wet Limestone Flue Gas Desulfurization System FGD Chemical Sample & Analysis Wuhan Kaidi Electric Power Environmental Co.

Sampling point as far as possible evenly distributed * It is best to take intermittent samples as limestone is being unloaded from the ship.Reactivity . 3 /61 Limestone Sampling & Analysis Preparation of Limestone samples Acquisition of limestone samples will be taken to the laboratory. * Collected samples shall be well-mixed for uniformity of samples to be analyzed. and the bottom of not less than 0. to conduct sampling.Moisture . and then be ground into powder.Grindability Index .Particle diameter . Each compartment of a sample collection.3 meters.2 meters. From the surface of not less than 0.Inert material Particle diameterǃgrindability indexǃMoistureǃinert materialǃCaCO3ǃ MgCO3ǃSiO2ǃFe2O3ǃAl2O3 4 . Collecting samples of well-mixed into a sample. the first analysis of particle size. Š Analysis Project of Limestone: . Limestone Sampling & Analysis Limestone sampling A compartment for a sampling unit.Raw limestone particle size . a component of the final. Sampling point should be from the car wall.

Limestone Sampling & Analysis Common components of Inert material no larger than 5% limestone Particle diameter < CaCO3 90%~95% 20mm MgCO3 1%~3% grindability index < 12 SiO2 1%~2% Moisture < 5% Fe2O3 1%~2% Al2O3 1%~3% 5 Limestone Sampling & Analysis Limestone analysis frequency Š Do not replace the limestone mine in the circumstances. its composition will not be much change. the composition analysis does not require a high frequency. * collect samples when each ship is unloaded. analysis of limestone can be less frequent 6 . But the limestone particle size and moisture content by artificial interference and weather significantly. * Based on consistency of limestone analysis between shipments. the need to strengthen analysis.