Different aspects to consider

selecting FGD type of technology

Lars-Erik Johansson
Power-Gen India & Central Asia, 19-21 April, 2012, New Delhi, India
Agenda

• 1st topic Introduction and classification of FGD

• 2nd topic Different type of FGD with main features

• 3rd topic Different aspects for considerations

• 4th topic Examples of evaluations

• 5th topic Conclusions

Page 2
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Emissions to Air and its Effects

Page 3
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
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WHO air quality guidelines
for major air pollutants

Page 4
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
SO2 Emission Requirements (mg/Nm3)

National Current
Standards Requirement
U.S. 250 (50) (3-4 y) <200
W. Europe 400 <200
E. Europe 400 - Uncapped <400
Pacific Case-By-Case <400
Japan 170-860 <200
Taiwan 1430 <400
South Korea 100-200
China 100-200 (50)
Efficiencies requested from 80 % up to 98 %
Page 5
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
First utility FGD in the world: London,
England

• Battersea Power Station - 1935

•Used alkaline Thames river
water to scrub SO2
•Scrubber was made of wood

•Worked fine – Stopped due to •Great Lo ndon Smog o f 1952

the plume

•Battersea power station – site of first

FGD

•2008: Newly unveiled plan for Battersea

Power Station Page 6
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Classification of post-combustion FGD
• Wet systems
- Operating at saturated conditions
- Using slurry or solution in the flue gas with nozzles to
create mass transfer between flue gas and liquid

• Complete dry systems

- Introducing dry absorbent (lime or bicarbonate)
- Limited performance without controlling the temperature

• DFGD operation with controlled temperature

- Spray dryer absorber – using a slurry
- Circulating Dry Scrubber or NID™ – using recycle solids in
combination with a fabric filter

Page 7
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
 Most common principles for
Flue Gas Desulphurisation (FGD)
FGD options FGD type End Product

Open Spray Tower

Gypsum
Lime/Lime Stone

Bubbling bed/
WET FGD Tray absorber Gypsum
Lime/Lime Stone

Flue Gas FGD Absorber

None
Desulphurisation Sea water

Spray Dryer
Sulphite
Absorber
Dry Options
(DFGD)
Circulating
Dry Scrubber/ Sulphite
NID
Page 8
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Agenda

• 1st topic Introduction and classification of FGD

• 2nd topic Different type of FGD with main features

• 3rd topic Different aspects for considerations

• 4th topic Examples of evaluations

• 5th topic Conclusion

Page 9
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
 Limestone WFGD Process Diagram

•STACK ABSORBER
•WATER
•SPRAY TOWER
ABSORBER

•ELECTROSTATIC •MAKE-UP
PRECIPITATOR WATER
•TO BALL
MILL TANK

•CHLORIDE
PURGE

•LIMESTONE

•HYDROCLONE

•AIR •BELT FILTER

•GYPSUM

•FROM MW DEWATERING
TANK
REAGENT
•BALL MILL Page 10
PREPARATION
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Limestone/Forced Oxidation
CO2
(Carbon dioxide)

H2O
(Water)

SO2
(Sulfur dioxide)
CaCO3
(Calcium carbonate, CaSO4•2H2O
limestone) (Calcium sulfate,
gypsum)
O2
(Oxygen)

SO2 + CaCO3 + ½O2 + H2O → CaSO4•2H2O + CO2

Page 11
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Typical LS WFGD

•CPS Energy, J.K. Spruce Unit 2, US, 750 MW

Page 12
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
DFGD – technology specific features
• Lime-based semi-dry FGD technology
• Control the temperature to meet high performance
• Multi-pollutant control: High efficiency removal of SO2,
SO3, PM, HCl, and HF
• Fuel flexibility of up to 2.5% sulphur coal or higher
• Several types
- Spray Dryer Absorber (SDA)
Slurry based
- Circulating Dry Scrubber (CDS)
Introducing water and recycle solids independently in one
or several high velocity sections (venturi’s)
- NID™
Premixing of recycle solids and water

Page 13
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Spray Dryer Absorber

CaO + H2O -> Ca(OH)2 + heat

SO2 + Ca(OH)2(s) -> CaSO3.½H2O(s) + ½H2O
Page 14
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Spray Dryer Absorber

Atomizing of slurry into small droplet by atomizing disc

(shown) or two-media nozzles
Page 15
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
NID™ Flow Schematics
Reactor

Mixing Zone

Injection Zone

Page 16
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
NID-C Modular Concept

• Multiple, independently isolatable

modules
• Dampers
- Upstream of reactor
- Downstream of FF compartment
• Nominal gas flows corresponding
to 15 - 70 MWel per module
• Can be designed to achieve
emissions guarantees at full load
with one module out of service

Allows for Turn-Down up to 60% without Recirculation

Page 17
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Recent development using Modular Design
(NID-C)

•Unit
1

•Stack

•Unit
2

Modularization Offers Arrangement Flexibility and

adaption to larger sizes
Page 18
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
 Modular Design (NID-C)
• Shop fabrication drastically
cheaper than field fabrication

• Allows high degree of shop

fabrication even with truck
shipment
- Reactors
- Inlet ducts
- Day silos
- Mixers
- Hydrators

• Barge access allows

further pre-assembly
- Fabric filter compartments
- Inlet/outlet plenums

Modularization Lowers Construction Costs

Page 19
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
 Recent NID-C application

Location Indian River, US

Capacity 410 MW

Fuel Coal, 2,5 % S

SO2 removal 96 % (75 PPM)

Others HCl, SO3, HF

Particulate, Opacity

Start-up 2012

DFGD, NID-C was most favourable evaluated, toward

other technologies
Page 20
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
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Sea Water Flue Gas Desulphurization
(SWFGD)

Sea Water

Reheat Clean
Flue Dust SO2
Flue
Gas Collector Absorber Equipment
Gas

Sea Water
Sea Water Treatment Air
Plant

Treated
Sea Water

Page 21
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express written authority, is strictly prohibited.
Sea Water Flue Gas Desulphurization
(SWFGD)

H+ + HCO3- + ↔ CO2 + H2O

(neutralisation) • CO2
SO2 + H2O ↔ SO32- + 2H+ • H2O
(absorption) (oxidation) • SO42-
SO32- + ½O2 → SO42-
Page 22
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Alstom SWFGD 3D Layout

ESP or FF GGH Absorber Absorber SWTP Aeration

Pump Fan

ID Fan Booster Fan

Page 23
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Discharge seawater quality

Sea Water Treatment Plant is a key for good discharge

quality

Page 24
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
 Haimen Power Plant
Location Haimen, P.R. China

Capacity 2 x 1000MW

Fuel Coal, 0.9 % S

Gas flow 3 426 000 Nm3/h

SO2 inlet 1960 mg/Nm3

(dry, 6% O2)
SO2 removal 95 %

Flue Gas Reheat GGH

Effluent pH >6.8
Start-up 2009
World’s Largest SWFGD for Unit Size
Page 25
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Agenda

• 1st topic Introduction and classification of FGD

• 2nd topic Different type of FGD with main features

• 3rd topic Different aspects for considerations

• 4th topic Examples of evaluations

• 5th topic Conclusions

Page 26
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Selecting FGD Technology

Economic aspects
•Capital cost
•Operating cost

Technical aspects
•Sulphur removal
•Reliability
•Space requirements

Commercial aspects
•Reliable supplier
•Proven technology
•Supplier guarantee
Page 27
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Selecting FGD technology – New or Existing
• Green-field
- Space can be planned, but different technologies give
different layout demands
- Some (wet) FGD technologies must be complemented with
particulate separation
• Brown-field
- Normally limitation in foot-print
- Existing AQCS-equipment and status have importance
- Reuse of stack
- Loss of revenue during installation
• Ready for retrofit
- CO2 capture ready – space requirements
- Increased emission demands

Page 28
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Selecting FGD Technology - Emissions
• Emissions of SO2 and other acid components
- Most technologies can handle the demands
• Liquid discharge
- Access to release Cl rich water
• Particulate
- DFGD technologies using fabric filters can handle the
particulate emissions
• Visible plume – dispersion of stack plume
- DFGD operate at high temperature than wet systems
- Reheat might be needed for wet systems
- DFGD technologies have higher efficiencies on SO3 – to
meet low opacity

Page 29
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Selecting FGD Technology - Cost

• Absorbent material
- DFGD needs quick lime with high quality to meet low
consumables and good control emissions
- Limestone, to be used within LS WFGD needs to be of
good commercial quality
- In case of sea water, access is needed – coastal areas
• NPV
- All cost to be included in OPEX and CAPEX
- Discount rate and evaluation time
- High rate and long time favor technologies with relative high
CAPEX and low OPEX
• Size of the plant
- Consumptions is normally proportional to the size
- Other operation normally less than proportional to the size
- Investment cost normally less than proportional to the size
Page 30
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express written authority, is strictly prohibited.
Typical key parameters for different
technologies - overview
Dry FGD Seawater FGD Limestone WFGD
Absorber NID or SDA Packed Tower Spray Tower
First Installation 1980 1968 1968
Features • Low investment • No reagent • High efficiency
cost • No by-product spray zone
• Dry by-product • Low cost reagent
• Small footprint • By-product flexibility
• Multi-pollutant
control
Reagent Lime Seawater Limestone
By-product Landfill Seawater Marketable gypsum or
landfill
Sulfur <4.5 % (NID) <1.5 % <6 %
Removal -98 % (NID) -98 % -99 %
Efficiency
Capital Cost 0.7X 0.8X X

Power 0.7 % 0.7-1.5 % 1.0-2.0 %

Consumption
(inc. booster
fans)
Aborbent Cost €80/ton €0/ton €20/ton
By-product Cost €5-10/ton €0/ton €5-10/ton – disposal
(€5/ton) – sale

Page 31
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Agenda

• 1st topic Introduction and classification of FGD

• 2nd topic Different type of FGD with main features

• 3rd topic Different aspects for considerations

• 4th topic Examples of evaluations

• 5th topic Conclusions

Page 32
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particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
FGD Technology Selection - Overview

DFGD – NID technology has expanded the range to large

plants
Page 33
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Example NPV calculation for different
technologies

Each case must be evaluated with the specific

conditions

Page 34
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express written authority, is strictly prohibited.
Agenda

• 1st topic Introduction and classification of FGD

• 2nd topic Different type of FGD with main features

• 3rd topic Different aspects for considerations

• 4th topic Examples of evaluations

• 5th topic Conclusions

Page 35
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Conclusions
• Many technologies has during the years been developed
with DFGD, LSWFGD and SWFGD as the preferred,
most widely spread technologies
• All established technologies can meet the demands for
SO2 removal for the Indian market
• All technologies have different consideration and often
related to operation and capital cost transferred to NPV
• Specifically for low to medium range sulphur content, the
DFGD and SWFGD will most probably be the preferred
total evaluated technologies

Reliable technologies exist to meet the future

market in INDIA, but each case must be evaluated
Page 36
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 Questions ?

Thank You
Page 37
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