Seawater FGD Technology

Kjell F. Nodland

FGD User’s Conference, Moline, IL

Sept. 16, 2008
 Agenda

• Introduction

• Environmental aspects

• Technical details

• Technical improvements

• Case studies

• Comparison with other FGD processes

Alstom SWFGD 2008 – p 2
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 Alstom seawater FGD

First plant in operation: 1968

Today more than 80 references

worldwide

Process has been used on:

- Coal and Oil-fired Power Stations

- Metal smelters

- Petrochemical industry / oil refineries

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 List of installations
Recent references for power plants...

• Shoaiba, 3 x 400 MW, Saudi Arabia (start-up 2011)

• Ventanas, 1 x 220 MW, Chile (2010)
• Longannet, 3 x 600 MW, Scotland (2008)
• Kilroot, 2 x 260 MW, N. Ireland (2008)
• Aberthaw, 3 x 485 MW, Wales (2008)
• Jimah, 2 x 700 MW, Malaysia (2008-09)
• Huangdao, 2 x 600 MW, China (2007)
• Tanjung Bin, 3 x 700 MW, Malaysia (2006-07)
• Vasilikos, 1 x 130 MW, Cyprus (2005)
• Manjung, 3 x 700 MW, Malaysia (2002-03)

Totally 84 plants / 30 600 MW capacity installed or under construction

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 Agenda

• Introduction

• Environmental aspects

• Technical details

• Technical improvements

• Case studies

• Comparison with other FGD processes

Alstom SWFGD 2008 – p 5
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 Sulfur recycling

SO2 H2SO4

SO2

SO4 SO4
SO4

Coal/Oil H2S
with Sulfur

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 Seawater is sulfate-rich

Other
Sulfate
2.1 Kg
2.7 Kg

Chloride
10.8 Kg 19.4 Kg
Sodium

1 m3 seawater

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 Water quality meets requirements

Inlet
Unit Discharge
seawater
pH 8.2 6-7

Sulfate mg/l 2 700 2 785

Temperature °C T T+1.5 - 2

Salinity ‰ 33.5 33.5

Suspended
mg/l SS < (SS + 1.0)
solids

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 Oxygen balance controlled

Inlet
Unit seawater Discharge

COD mg/l O2 0 < 2.5 – 5.0

DO % 50 – 100 70 – 90

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 Effects assessment

• Environmental impact assessment (EIA)

− Assess no-effects limits of the components
− Model discharge dispersion and dilution
− Estimate theoretical effects zones in the specific
situation(s)
− Evaluate the extent and severity of potential effects

• Environmental monitoring
− Design of monitoring strategy
− Perform sampling, measurements, and analyses
− Interprete results against predictions from the EIA

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 Agenda

• Introduction

• Environmental aspects

• Technical details

• Technical improvements

• Case studies

• Comparison with other FGD processes

Alstom SWFGD 2008 – p 11
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 Alstom Seawater FGD process

Seawater

Reheat Clean
Flue Dust SO2
Flue
Gas Collector Absorber Equipment
Gas

Seawater
Seawater Treatment Air
Plant

Treated
Seawater

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 Simple operation and maintenance

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 Power generation industry

UNELCO, Spain Manjung, Malaysia

Oil-fired PP Coal-fired PP
4 x 80 MW 3 x 700 MW

SHENZHEN, China PAITON, Indonesia

Coal-fired PP Coal -fired PP
3 x 300 MW 2 x 670 MW

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 Small units, GRP absorber

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 Wet stack, no GGH

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 Retrofit, beside main duct

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 Green field, below main duct

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 Greenfield, aerial view

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 Absorber design, once through

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 Centrifugal fan

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 Axial Fan

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 Gas Gas Heat Exchanger

GGH Arrangement

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 GGH, protection against corrosion

Grey colour is the extent of the

lining

Enamelled Heating Elements

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 Flue Gas Dampers
Function: To isolate the FGD unit
• for maintenance purposes
• for protection of the FGD unit

Damper type:
• Double bladed / Tandem with seal air for
mansafe access to the absorber and GGH
• By-pass damper single bladed

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 Damper seal air fan

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 Seawater treatment plant (SWTP)

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 SWTP, working as a seal pit

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 Absorber pumps

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 Aeration fan, constant water level

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 Aeration blower, varying water level

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 Agenda

• Introduction

• Environmental aspects

• Technical details

• Technical improvements

• Case studies

• Comparison with other FGD processes

Alstom SWFGD 2008 – p 32
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 R&D activities, Reduced size

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 Agenda

• Introduction

• Environmental aspects

• Technical details

• Technical improvements

• Case studies

• Comparison with other FGD processes

Alstom SWFGD 2008 – p 34
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 Manjung Power Station

Location Perak Darul

Ridzuan, Malaysia

Capacity 3 x 700 MW

Fuel Coal, 0,70 % S

Gas flow 2 610 800 Nm3/h

SO2 inlet 628 vppm

SO2 removal 96 % in absorber

Flue Gas Reheat GGH, 80°C

Start-up 2002 - 2003

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 Manjung plot plan

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 Manjung GA

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 Manjung 3 x 700 MW

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 Ventanas plot plan

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 GA, gas handling unit

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 Agenda

• Introduction

• Environmental aspects

• Technical details

• Technical improvements

• Case studies

• Comparison with other FGD processes

Alstom SWFGD 2008 – p 41
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 Principal FGD processes

FGD Process Features Reagent Byproduct

SO2 absorption with
Seawater
seawater in scrubber. None None
FGD
Seawater treatment
Lime injection in flue CaO or Ca SO3 x 1/2 H2O
gas stream. Dry by- Ca(OH)2
Dry FGD Calsium sulfite for
product removed by Lime or slaked commercial appl.
filter lime or landfill
Re-circulation CaSO4 x 2 H20
limestone slurry Ca CO3
Wet Gypsum
sprayed in absorber
Limestone
tower. Aeration and de- Limestone commercial grade
watering / land fill

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 Alternative Scrubbing Processes
Dry FGD Seawater FGD Limestone WFGD
Latest Technology SDA or FDA Alstom SWFGD Advanced WFGD
Features - Low investment - No reagent - High efficiency spray
cost - No byproduct zone
- Dry byproduct - Low energy - Low cost reagent
- Small footprint consumption - Byproduct flexibility
- No liquid waste

Reagent Lime Seawater Limestone

Byproduct Landfill Seawater Marketable gypsum or
landfill
Sulphur <2.5 % <1.5 % (economical <6 %
range thermal power
plants)
Removal efficiency 90-95 % >95 % >95 %
Capital cost 0.7X 0.8X 1.0X
Power Consumption 0.7 % 0.7-1.0 % 1.0-2.0 %
(inc. booster fans)
Reagent Cost $60/ton $0/ton $15/ton
Byproduct Cost $5-10/ton $0/ton $5-10/ton – disposal
($5/ton) - sale

Note: €1 approx. equal to $US 1.5

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 Economical over a wide range

Wet Limestone

High
Sulfur Content

Dry FGD Seawater FGD

Medium

Low Spray - Dry

Low Medium High

Flue Gas Volume

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