FLUE GAS DESULFURIZATION (FGD)

Wet Limestone Gypsum Process

1,000 MW Power Plant

(Non-Leakage Type GGH, Low Temp. ESP)

Source : SCR Technology and Standard, KOPEC, 2008>

Prepared by J.O.Weon
 - Contents -

Ⅰ. Overview of Wet FGD Process

Ⅱ. Design Parameters

III. System Description (Components & Features)

IV. References of FGD System

Ⅰ. Overview of Wet FGD Process
FGD (Flue Gas Desulphurization) SYSTEM is facility which
removes SO2 in flue gas physic-chemically using alkaline
as the sorbent. Generally, SO2 is generated by fossil fuel
combustion in boiler. Treated gas from FGD system is
emitted to the atmosphere from a stack.
The FLUE GAS WET SCRUBBING SYSTEM using limestone
which is plentiful and inexpensive as the sorbent and
producing gypsum as a byproduct represents the standard
process worldwide for flue gas desulphurization.

The FGD system is characterized by a number of special

advantages: In the first place it offers high SO2 capture
efficiencies together with high plant availability. The
consumption of sorbent is low and the byproduct is
gypsum in a usable form.
 Chemical Reaction of Wet FGD System

• Simplified Chemical Reaction in Absorber

– Absorption
SO2 + H2O ⇒ HSO3-
CaCO3 + 2H+ ⇒ Ca2+ + CO2 + H2O

– Oxidation
HSO3- + ½O2 ⇒ SO42- + H+
Ca2+ + SO42- + 2H2O ⇒ CaSO42H2O
II. Design Parameters
SO2 removal efficiency : ≥ 95.6%
Stack inlet temperature : ≥ 101℃
Carryover Mist Content : ≤ 30㎎/㎥
GGH Leakage : ≤ 1%
Gypsum
- Free moisture : ≤ 10%,
- Purity (CaSO4 2H2O) : ≥ 95%
Ball Mill Capacity : ≥ 24ton/hr
Vacuum Belt Filter Capacity
(dry base) : ≥ 38ton/hr
WWT Capacity(ZLD) : ≥ 32㎥/hr
Ⅲ. System Description (Components & Features)
– Absorber & Auxiliary System
– Flue gas draft & Reheating System
– Limestone Slurry Preparation System
– Gypsum Dewatering System
– FGD Waste Water Treatment System
Process Flow Diagram
1) Absorber & Auxiliary System
Absorber
is the most important facility to guarantee the
performance of FGD System.
Diameter and height of absorber influence on contact
Time with sorbent, pressure, velocity of flue gas. It is
connected with SO2 removal efficiency directly.
Absorber is open spray tower type with single loop and
has 6 (100% x 4, 50% x 2) spray banks.
Each spray bank connects each absorber recirculation
pump and it transfers limestone slurry inside absorber
reaction tank. Distance between each spray bank is
1.7/2.0m (Operation : 3~5 spray banks / Standby : 1
spray bank)
Transferred limestone slurry is sprayed through spray
header and spray nozzle and contacts with untreated gas
to remove SO2 in flue gas.

After flue gas passes the absorption zone, it goes

through 3 internal mist eliminators to remove mist in
flue gas. After that flue gas passes GGH (Reheater) and is
exhausted to the air from a stack.
Oxidation air blower is installed to provide oxygen which
is necessary to oxidize calcium sulfite in reaction tank.
Oxidized calcium sulfite becomes gypsum.

CaSO3 + 1/2O2 + 2H2O --> CaSO4.2H2O

Absorber & Aux. system is consist of absorber (ABS),

absorber recirculation pumps (ARPs), mist eliminators (MEs),
oxidation air blowers (OABs), Gypsum bleed pumps (GBPs)
and so on.
2) Flue Gas Draft & Reheating System

Flue gas leaving the particulate control system passes

through GGH (Cooler) to decrease flue gas temperature and
enters the FGD absorber in which SO2 is removed .
Scrubbed flue gas passes the GGH (Reheater) to be
reheated to keep minimum 90℃ and is exhausted to the air
from a stack.
Combine induced draft fan (CID fan) is installed to be
overcome pressure loss of FGD system. There are boost up
fans (BUFs) in other projects that preceded.
To protect equipment from abnormal operation condition
of boiler and FGD system, emergency system is included in
flue gas draft & reheating system.

- Emergency bypass damper

- Emergency quenching system

Flue gas draft & reheating system is consist of

GGH (Cooler / Reheater), FGD inlet damper, FGD outlet
damper, emergency bypass damper, emergency quenching
system, duct and so on.
3) Limestone Slurry Preparation System

Limestone slurry preparation system pulverizes limestone

(Max. 20㎜) which is used as an alkaline sorbent and makes
limestone slurry. Required output fineness is 95% or higher
through 325 mesh.

Ring main is consisted therefore, limestone slurry is supplied

to the absorber in a continuous loop to minimize pipe
plugging.

Limestone slurry preparation system is consist of weighing

feeders, wet ball mills, mill classifiers, mill slurry tanks, mill
slurry pumps, limestone slurry storage tanks, Limestone
slurry feed pumps and so on.
4) Gypsum Dewatering System

To produce useable gypsum, absorber slurry which reacts

with SO2 is transferred to vacuum belt filter to dewater
and reduce chloride concentration by gypsum bleed pump
via primary hydrocyclone.

Hydrocyclones dedicated to and absorber module are

used for primary gypsum slurry dewatering.
Hydrocyclone are fed flurry from gypsum bleed pump.
It separates filtrate water (includes fine particles) and
gypsum slurry (includes large particles) by the centrifugal
force.
Vacuum belt filter which is second dewatering equipment
dewaters the gypsum slurry to meet below requirements.
- Moisture content ( ≤ 10%)
- Chloride concentration ( ≤ 100ppm).

Gypsum dewatering system is consist of gypsum

dewatering hydrocyclone, vacuum belt filter, filtrate tank,
gypsum slurry storage tank, 2nd stage hydrocyclone feed
tank, FGD wastewater transfer tank and so on.
 Ⅳ. References of FGD System
1) Tangjin Thermal Power Plant Unit 1~4 FGD

2) KDHC, Chung-Ju FGD Plant

3) Youngnam Thermal Power Plant Unit 1&2 FGD

4) Bridgestone Carbon Black Thailand Company

5) Thai Tokai Carbon Product Company

6) Daegu Dyeing Industrial Center FGD

7) Samchonpo Thermal Power Plant Unit 1~4
FGD

8) Jeju Thermal Power Plant Unit 1&2 FGD

9) Hadong Thermal Power Plant Unit 7&8 FGD

10) Hsinta Thermal Power Plant Unit 1&2 FGD

11) Youngheung Power Plant Unit 5&6 FGD

Tangjin Thermal Power Plant 1
Tangjin Thermal Power Plant 2
EP & FGD
Flue Gas Draft & Reheating System
Absorber & Auxiliary System
Waste Water Treatment
Chung-Ju FGD Plant
Flue Gas & Absorber System
Auxiliary System For FGD
Hadong Thermal Power Plant unit 7&8 FGD
Hadong Thermal Power Plant unit 7&8 FGD
Hsinta Thermal Power Plant unit 1&2 FGD
Hsinta Thermal Power Plant unit 1&2 FGD
Yeongheung Thermal Power Plant unit 5&6 FGD
Yeongheung Thermal Power Plant unit 5&6 FGD
Absorber Recirculation pump
(600GSL / 6800㎥/hr)
Absorber Recirculation pump
(700GSL / 7000㎥/hr)
Absorber Recirculation pump
(800GSL / 10500㎥/hr)
Spray Header & Nozzle
Spray Header & Nozzle
Absorber Internal Spray Header & Spray Nozzle
Mist Eliminator
Absorber Outlet & Mist Eliminator(3’rd Stage)
Mist Eliminator Washing
Absorber Agitator(side entry)
Oxidation Air Blower
Tandem Damper
GGH Heat Element
GGH Rotor & Heat Element
Weight Feeder
Weight Feeder
Ball Mill
Ball Mill
Hydro Cyclone
Vacuum Belt Filter
Vacuum Belt Filter
Vacuum Pump