Enhancing Capacity – Empowering Nation

Technological Parameters in selecting systems to

control emissions in Thermal Power Plants

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Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
New Delhi Jan 2017
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Environmental Gazette Notification

Water Requirement : 3.5 m3/Mwh (max.) (current)
(with cooling tower)
: 2.5 m3/Mwh (> 2017)
Technology Options : (i) Air‐cooled condenser 
(Boiler) (ii) Dry bottom ash handling system

Particulate matter : 100 mg/Nm3 (vintage plants before 31.12.2003)

: 50 mg/Nm3 (2003 – 2016) 
: 30 mg/Nm3 (> 2017)
Technology options : Already available
Sulphur Di‐oxide : 200 mg/Nm3 (upto 2016)
: 100 mg/Nm3 (> 2017) 
Technology options : BAP having collaboration with MHI
NOx : 600 mg/Nm3 (vintage plants)
: 300 mg/Nm3 (2003 – 2016)*
: 100 mg/Nm3 (> 2017)**
Technology options : *Modification of firing system (to be checked based on existing 
layout and structural arrangement)
** Separate De NOx Plant

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Comparison of Emission Norms

World Bank Environmental EU China The Gazette

Norms Protection 2012 of India
2008 Agency, USA 2016
2012
Particulate Matter 30 22.5 50 30 30
mg/Nm3

Sulphur Dioxide (SO2) 200 160 200 100 100

mg/Nm3

Oxides of Nitrogen 200 117 200 100 100

( NOx) mg/Nm3

Mercury ( Hg) mg/Nm3 - 0.001 - 0.03 0.03

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 Enhancing Capacity – Empowering Nation

Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
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NOx Fundamentals– Forms of NOx

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NOx Fundamentals– Introduction

Fuel NOx:
• Forms when Nitrogen that is chemically bound in the fuel reacts with oxygen in the
combustion air.
• This process is not significantly temperature dependent but does depend on Air Fuel ratio .

Thermal NOx:
• Combustion process above 1300 deg C form “Thermal Nox” and this process is defined
by Zeldovitch Mechanism
• Formation of thermal NOx depends on oxygen concentration and temperature and
insignificant below 760 deg C

Prompt NOx:
• Forms when Nitrogen in combustion air or fuel reacts with Hydrocarbon radicals
from the combusting fuel or when some of the fuel bound Nitrogen forms HCN. This
process is dependent on fuel rich conditions. - Negligible
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Intensity of various NOX Components in Boiler

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Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
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Major NOx Reduction Techniques

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NOX Control using Combustion Process

Modification

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Low NOx Burners and Furnace Air Staging

Design features that regulate the  aerodynamic distribution and mixing of the fuel 
and air.

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Furnace Air‐staging

• Combustion is made to
occur in two zones
• Fuel rich zone near the
flame. (70‐90% air is
supplied here) OFA, separated
• Remaining combustion
OFA, close coupled
in the low temperature
zone above the flame
Primary air and Secondary air

Furnace leakage

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NOx control using Flue Gas Treatment – Post

Combustion

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SELECTIVE NON CATALYTIC REDUCTION

Combustion
Process

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SNCR Reaction Equation

Ammonia reaction equation

2NO + 2NH3 + (1/2)O2 2N2 + 3H2O

Reaction for urea

4NO + 2CO(NH2)2 + O2 4N2 + 4H2O + 2CO2

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SELECTIVE NON CATALYTIC REDUCTION

• In Furnace Post Combustion Control

• Injection in Upper Furnace

• Temperature Range: 900‐1100 deg C

• NOx reduction Range for Utility Boilers ‐ 25 to 50 %

• Urea or ammonia can be used as the reagent.

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SNCR Design Temp Window

Source EPA

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SNCR Critical Process Parameters

• Reaction temperature (sp.: furnace temp) 

• Residence time (reagent injection location) 

• Degree of mixing 

• NOx concentration

• Ammonia slip (which is strongly influenced by the ratio of injected 
reagent to uncontrolled NOx) 

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SELECTIVE CATALYTIC REDUCTION

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SELECTIVE CATALYTIC REDUCTION

In an SCR system, vaporised ammonia (NH3) is injected into the flue‐gas stream at about 300–400°C,
which is then passed over a catalyst. The catalyst promotes reactions between NOx and NH3 to form
molecular nitrogen and water vapour.

NOX NH3 Basic Reactions

4 NO + 4 NH3 + O2  4 N2 + 6 H2O
2 NO2 + 4 NH3 + O2  3 N2 + 6 H2O

Undesired Parallel Reactions

SO2 + 1/2 O2  SO3
NH3 + SO3 + H2O  NH4HSO4
N2 H2O

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Options to reduce NOx emission: Case to Case Basis

Option‐1 * :
Introduction of Over Fired Air and /or Concentric Firing System 
without disturbing existing WB

Option‐2 * :
Introduction of New WB with additional level Separated Over 
Fired Air without changing total furnace height.

Option‐3 * :
SNCR in boiler to reduce Nox

Option‐4 * :
Introduction of SCR

* Can be decided based on the site measured values
New Delhi Jan 2017
 Enhancing Capacity – Empowering Nation

Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
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SCR DESIGN PROCESS

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Basic SCR Configurations

NH3
AIR FLUE GAS
HEATER DESULFURIZATION
BOILER

STACK
HOT-SIDE, HIGH DUST SCR SCR
 Recommended
ELECTROSTATIC
PRECIPITATOR

NH3
AIR
HEATER
BOILER

STACK
HOT-SIDE, LOW DUST SCR SCR Hot ESP
ELECTROSTATIC FLUE GAS technology not
PRECIPITATOR DESULFURIZATION
successful
GAS TO GAS
HEAT
AIR FLUE GAS EXCHANGER
HEATER DESULFURIZATION

STACK
BOILER
COLD-SIDE SCR Very costly
ELECTROSTATIC Including GGH
PRECIPITATOR

DUCT BURNER
NH3
SCR

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SCR Process Flow Diagram

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SCR Catalyst
 The primary base material of catalyst is titanium dioxide (TiO2), with smaller amounts of other
metal oxides including tungsten oxide (WO2) for thermal support and vanadium pentoxide
(V2O5), which is the primary active material.

 Two predominant styles of catalyst are used in SCRs ‐ honeycomb and plate type.

 Honeycomb catalyst provides the greater surface area of the two designs, but can be
susceptible to fly ash fouling.

 BHEL has capability to manufacture both honey comb as well as plate type catalysts

HONEY COMB PLATE TYPE

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Comparison Of SCR Reagent Injection Systems

Anhydrous Ammonia Aqueous Ammonia Urea to Ammonia

(19 or 29% by weight NH3)

Lowest capital cost Moderate capital cost Highest capital costs

Lowest operating cost High energy usage Moderate energy consumption

Fewest product deliveries Largest number of product deliveries Moderate product deliveries

Highest safety risk Lower risks than anhydrous Lowest safety risk

Highest permitting costs Moderate permitting issues Lowest permitting issues

Largest number of regulatory issues Moderate regulatory issues Lowest regulatory issues

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NH3 Slip
• NH3 may reduce NOx, oxidize to form NOx, or remain unreacted
and pass through the stack. This unreacted portion is referred to as
“NH3 slip”.
• Inadequate flue gas temperature and/or reaction time for SNCR
kinetics and mixing of the reagent with flue gas can contribute to
an increase in NH3 slip.
• Relatively high concentrations of NH3 slip can react with SO2 and
sulphur trioxide (SO3) in the flue gas and form ammonium sulfates
and bisulfates, which, in turn, can cause plugging of the air
preheater (APH) passages.
• The potential for APH fouling can be alleviated by maintaining
NH3 slip levels between 2 and 5 ppm.

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SCR system
NOx Emission of 100 mg/Nm3 at SCR outlet
SCR System : to be installed with 
associated design modifications 
The main SCR components & subsystems are as given 
below, considering anhydrous ammonia as reagent
Reactor
Catalyst
Ammonia Unloading
Ammonia Storage
Vaporisers
Dilution Fans
Ammonia Distribution
Ammonia Injection
Static Mixing
Turning Vanes
Soot Blowing
Ammonia Tank : to be designed and located as per 
the IS 4544 code. Tank location to be identified in the 
existing Power Plant area, considering the existing 
structures, structures, facilities, pipes, drains, 
overhead lines etc.

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SCR system
NOx Emission of 100 mg/Nm3 at SCR outlet

SCR System : to be installed with associated design modifications 
SCR system would reduce the stack outlet NOx emission to 100 mg/Nm3 from 500 mg/Nm3

SCR system Installation : installed in the Flue Gas between Eco & APH. Temperature range in this zone
is optimal for NOx reduction.

SCR system Location : located between Economiser and APH

SCR system Ducting : optimally designed Inlet & Outlet Ducting with suitable internals for uniform
distribution of Flue Gas and proper mixing of the reagent.

SCR system Structurals : adequate & suitable for support and maintenance of the SCR & its allied sub
systems.

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TYPICAL PLANT WITH SCR

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TYPICAL PLANT WITH SCR

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 Enhancing Capacity – Empowering Nation

TYPICAL PLANT WITH SCR

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 Enhancing Capacity – Empowering Nation

Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
New Delhi Jan 2017
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Technical Issues
• NOx measurement –Avg or Instantaneous; Location of measurement-
Clarity required in Gazette notification
• Type of reagent for SCR to be chosen
• Anhydrous Ammonia-Transportation/Handling.
• Aqueous Ammonia- Storage space
• Urea-Technical grade urea required (Total Nitrogen by weight min.
46%)-IS 1781 ; currently to be imported.
• Location of Ammonia storage tank-a)Static and Mobile Pressure
Vessels b)IS4544 c) ANSI K61.1d)IS 662/799

New Delhi Jan 2017

 Enhancing Capacity – Empowering Nation

Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
New Delhi Jan 2017
 Enhancing Capacity – Empowering Nation

Modification Required for SCR

A) Boiler Back End system : modifications required to accommodate the SCR System. 

B) ID system to be modified to handle the additional pressure drop due to the SCR 
System.

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Boiler Back End

complementing the SCR installation

Boiler Back End system : modifications required to accommodate the SCR System. 
Boiler Back End to be modified to accommodate the SCR & and its sub Systems.

Ducting system : additional Ducting from Eco‐Out to SCR‐In and from SCR‐Out to APH In.

Dampers : additional Biplane Dampers for Isolation & Control. Existing Gates at
APH Flue Gas Inlet would be replaced with Dampers.

Ash Handling system : additional provision of Ash Handling from SCR Inlet & Outlet Ducts.

Air Preheaters : upgraded APH Rotor, Housing, and Elements capable of handling the Flue Gas
from the SCR. Adequate provision for APH Internals Cleaning.

Supporting Structures : augmented Supporting Structures to support the additional equipment &
loads by providing additional / replacement / strengthening structures.

Foundation Design : redesigned and augmented to complement the structural changes.

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ID system
complementing the SCR installation

ID system : modifications required to complement the introduction of SCR System. 
ID system to be modified to handle the additional pressure drop due to the SCR System.

ID Fan : ID Fans & Motor with higher capacity, to handle the additional
pressure drop in the SCR system and or Cyclone seperator.

Dampers : higher torque actuators for the Dampers in the ID system, to take care of
the higher negative pressures inside duct due to the addition of the SCR.

Ash Handling system : additional provision of Ash Handling.

Supporting Structures : Supporting Structures to support the additional equipment &

loads by providing additional structures.

Foundation Design : redesigned and augmented to complement the structural changes.

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Modification Required for SNCR

• Adequate wall space within the boiler for installation of 
injectors have to be checked.
• The injectors have to be installed in the upper regions of the boiler, 
the boiler radiant cavity, and the convective cavity.
• Existing water tubes may need to be moved or removed from
the boiler housing.
• Adequate space adjacent to the boiler for the distribution system
equipment and for performing maintenance have to be checked. 

New Delhi Jan 2017

 Enhancing Capacity – Empowering Nation

Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
New Delhi Jan 2017
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NOx Emission reduction Summary

Modifications required to meet latest MoEF norms for Nox
Boiler Modification (Furnace / Backpass / Pressure Parts / Circulation system). 

Windbox.

Primary & Secondary Air system.

SCR to be installed between Eco Outlet & APH

Additional Ducting & Dampers for the new SCR System to be provided.

APH (with new internals & height) if required.

ID fan & motor with higher capacity.

ID system Dampers to be provided with higher rated actuators.

Structures and its foundation to be done.

Ammonia Unloading and Storage system to be located and designed according to the Code.

New Delhi Jan 2017

 Enhancing Capacity – Empowering Nation

Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
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PURPOSE OF FGD
The Flue Gas Desulphurization(FGD) is a process of removal of sulphur dioxide
(SO2) from the flue gas.

Sulphur content in Indian coal ranges from 0.25 to 0.5 % and in imported coal
it is more than 0.6 %.

95 – 96 % of sulphur is converted into SO2

Coal with 0.5 % Sulphur, generates SO2 of range 1500 - 2000 mg/Nm3

SO2 emission results in Acid Rain, corrosion of Buildings & Structures and
affect human health.

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 Enhancing Capacity – Empowering Nation

Environmental Gazette Notification

Water Requirement : 3.5 m3/Mwh (max.) (current)
(with cooling tower)
: 2.5 m3/Mwh (> 2017)
Technology Options : (i) Air-cooled condenser (North Karanpura 660 MW)
(Boiler) (ii) Dry bottom ash handling system (Durgapur 250 MW)

Particulate matter : 100 mg/Nm3 (vintage plants before 31.12.2003)

: 50 mg/Nm3 (2003 – 2016)
: 30 mg/Nm3 (> 2017)
Technology options : Already available
Sulphur Di-oxide : 100 mg/Nm3 (> 2017)
: 200 mg/Nm3 ≥500MW and 600 mg/Nm3 < 500MW (up to 2016)
Technology options : BAP having collaboration with MHI
NOx : 600 mg/Nm3 (vintage plants)
: 300 mg/Nm3 (2003 – 2016)*
: 100 mg/Nm3 (> 2017)**
Technology options : *Modification of firing system (to be checked based on existing
layout and structural arrangement)
** Separate De NOx Plant

New Delhi Jan 2017

 Enhancing Capacity – Empowering Nation

Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
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 Enhancing Capacity – Empowering Nation

TYPES OF FGD
1) Dry FGD (Lime based)

2) Seawater based FGD

3) Wet Limestone based FGD process

 Reagent : Limestone slurry
 Most widely used FGD system, having a share of about 80%.

New Delhi Jan 2017

 Enhancing Capacity – Empowering Nation

Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
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WET LIMESTONE BASED FGD

• Limestone is used as a reagent for the removal of SO2 from the exhaust flue
gas.
• The SO2 laden flue gas reacts with the limestone slurry sprayed in the
scrubber.
• The removal of SO2 takes place in the Absorber system and Gypsum is
collected as final product.
• Clean gas passes through the mist eliminator to remove moisture, gets
reheated in GGH and then discharged to chimney

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WET LIMESTONE BASED FGD

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DCFS – Double Contact Flow Scrubber

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Critical Equipment of FGD system

 Booster Fan

 Gas to Gas Heater (GGH)

 Slurry Recirculation pump

 Wet Ball Mill

 Gypsum de-watering system

 Oxidation Blower

 Mist eliminator

 Agitator

New Delhi Jan 2017

 Enhancing Capacity – Empowering Nation

Environmental Gazette Notification 2015

Part A-NOX
1. NOx Fundamentals
2. Major NOx Reduction Techniques
3. SCR Design Features
4. SCR Technical Issues
5. Modification for SCR and SNCR
6. Summary

Part B - SOX
1. Purpose of FGD
2. Types of FGD
3. Wet Limestone based FGD
4. BHEL Experience
New Delhi Jan 2017
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BHEL EXPERIENCE

 Successfully commissioned sea water based FGD at Trombay

unit#8 250 MW of MHI Technology in 2010

 Supplied Wet Limestone based FGD to NTPC Bongaigaon

3X250MW of Ducon Technology in 2012.

 BHEL has signed a TCA with M/s MHPS for Wet FGD
technology in April 2013 valid upto 2028.

 Received NOA for Maitree Bangladesh 2X660 MW EPC

contract which includes FGD system.

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Inputs from customer

Type of coal used/planned for boiler Customer input

Lime stone sourcing Customer input

Gypsum sales / disposal plan Customer to decide

13
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FGD Design inputs

• Coal analysis report & Flue gas characteristics

• Lime stone characteristics

• Process water characteristics

• Plot plan

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New Delhi Jan 2017