Environmental Control System for Thermal Power Plants

DESOx, DENOx and CCS

Working today for tomorrow's world

The future of our planet and the lives we lead is at stake. To progress, we must develop new and better ways to satisfy society's growing energy needs. Yet, at the same time, we must guarantee safety-improving our methods, while protecting the environment. At Babcock-Hitachi K. K., we are a world leader in energy-related technologies and environmental systems. Our power and industrial plant boilers improve plant performance, while our ue gas desulfurization systems (DESOx) , NOx removal systems (DENOx) and CO2 capture system (CCS) protect the environment. Our technologies lend new found quality and security to vital industries. We are constantly updating our research to better meet the needs of our clients.

Kure Division of Babcock-Hitachi K.K.

Operation Start: November, 1959 Facilities: Manufacturing of boiler plants, desulfurization plants (DESOx), nuclear power plant equipment, industrial plants and incineration facilities
ISO9001 Established quality program and succeeded to get the initial certi cate of approval on July 12, 1994.

Akitsu Works of Babcock-Hitachi K.K.

R&D and Commercialization Record

1963 1970 1972 1974 1976 1978 1980 1982 1984 1986 1990 1995 2000 2005 2010 2015 2020 2025

DESOx R&D

Tray Tower R&D Spray Tower R&D Advanced Spray Tower Commercialization

DENOx
R&D

R&D Catalyst Composition Catalyst Con guration Pellet type Catalyst Con guration Plate type Commercialization

Operation Start: March, 1987 Facility: Continuous automatic manufacturing process of catalyst Site Area: 127,000 m2

CCS

R&D Activity Pilot Test at Power Plant Demonstration Plant Commercialization

Global Network
As a core company of the Hitachi, Power & Industrial group, we provide boiler and AQCS services globally.

l l l l

l Babcock-Hitachi K.K. l Babcock-Hitachi (Philippines) Inc. l Babcock-Hitachi Dongfang Boiler Co.,Ltd l Hitachi Power Europe GmbH l Hitachi Power Systems America, Ltd.

Environmental Control Systemfor Thermal Power Plants

DESOX
Flue Gas Desulfurization Systems
In the early 1960s, before other commercial enterprises got on the bandwagon, Babcock-Hitachi K.K. (BHK) began developing Flue Gas Desulfurization systems (FGD). Our rst commercial system went into operation in April, 1974. Then, as a result of continuous technical improvements, our rst 1,050 MW plant started up in 2000. FGD system technology of BHK is contributing to the prevention of air pollution not only in Japan but also in European countries, the USA and Asian countries.

Environmental Control Systemfor Thermal Power Plants

Principle & System Flow

BHKs FGD system uses the latest type of spray tower (advanced spray tower) combining three important functions; oxidation, both SO2 and particulate removal. This advanced system requires less equipment, less space and fewer utilities than its predecessors.

DESOx Flow Diagram

Bypass Damper Limestone Stack

ESP Boiler

Fan

Limestone Silo

Gas-Gas Heater

Process Input

Mist Eliminator

SO2 Flow

Gypsum Dewatering

pH

Oxidation Blower

Absorber

Electric Power Development Co., Ltd. (Japan) Tachibanawan Power Station, No. 2 Unit
The largest DESOx plant in Japan
Boiler Fuel: Size: Gas Capacity: Conc. of Inlet SO2: SO2 Removal Ef ciency: FGD Con guration: Absorber Type: Gas Reheating System: Placed in Operation: Coal 1,050 MW 3,300,000 m3N/h 809 ppm 94% or more New Flue Gas Treatment System Advanced Spray Tower Non-Leakage Gas-Gas Heater Dec., 2000

Control Signal

Absorber Recirculating Pump

Gypsum

Chemical Principle of FGD

SO2 Absorption and Oxidation SO2+2H2O+CaCO3 (Limestone) +1/2O2 CaSO4

2H2O (Gypsum) +CO2

DESOX
Summary of Latest Technology Improvement
The following design concepts are adopted in our advanced FGD systems: 1. Higher gas velocity 2. Decrease of spray stages and better liquid/gas contact. 3. Higher slurry concentration 4. Effective in-situ forced oxidation

Environmental Control Systemfor Thermal Power Plants

CFD Model Study

BHK has CFD model simulation technology. In the simulation, absorber internal gas distribution which in uences to SO2 removal performance is analyzed with track of spray droplet and behavior of Gas-Liquid contact. The optimization is done based on the result of CFD study for internal parts arrangement such as spray nozzles as well as absorber shape partially.

1. Higher Gas Velocity

Increase of SO2 Removal Ef ciency

2. Decrease of Spray Stages

Track of Spray Droplet

Droplet

R&D Test Facility

In addition to the analysis utilizing software, BHK owns test facilities for Absorber test and one-through pilot test from boiler to stack. With these facilities, it can be performed the studies on each project basis.

Flow Model Results

Gas Velocity: < 3m/s

Gas Velocity: = 3 5m/s

SO2 Removal Ef ciency (%)

Slurry Gas Liquid/Gas Ratio = Constant

Pressure Drop

Gas Velocity

Slurry Gas

3. Higher Slurry Concentration

Limestone Gypsum

4. Effective In-Situ Forced Oxidation

Absorber Test Facility One-through Test Facility from Boiler to Stack

Low Concentration

High Concentration

Feature of BHK FGD System

Air Air

SO2 Removal Ef ciency (%)

BHK is capable to offer the advanced FGD system containing the following features adopting technology improvement. 1. Excellent advanced spray tower absorber featuring ; 1) High SO2 and dust removal ef ciency 2) Low utility consumption due to excellent liquid / gas contact and lower pressure drop 3) Higher oxidation performance 2. Full support by R&D facility 3. Proven FGD technology and high reliability

Tiny Bubbles Less Air Required

Slurry Concentration

No Plugging

DESOX
Non-Leakage Gas-Gas Heater
Typical Con guration
Untreated Gas Heat Recovery Section

Environmental Control Systemfor Thermal Power Plants

New Flue Gas Treatment System with Ultra-low Dust Emission

This equipment recovers heat from the ue gas and reheats the treated ue gas for FGD plants without any ue gas leakage from untreated to treated side and vice versa. To comply with increasingly more stringent emission regulations, this type of gas-gas heater is indispensable. BHK has developed a new ue gas treatment system consisting of ESP, FGD plant and gas-gas heater, which realizes effective treatment of ue gas so that the system can keep dust emissions well within stringent regulations. This new ue gas treatment system of BHK has already been patented in Japan.

New Flue Gas Treatment System

Boiler DENOx A/H GGH ESP IDF DESOx GGH
(Reheat ) (Heat Recovery) 90 100C

Reheat Section

Stack

Conventional Flue Gas Treatment System

Boiler DENOx A/H ESP
130 140C

GGH IDF
(Heat Recovery)

DESOx

GGH
(Reheat)

Treated Gas

Sample of Heat Tube

Stack

Typical Flow Sheet

Heat Transfer Medium Heater

Auxiliary Steam

Heat Transfer Medium Tank

The new system has the following features: 1. Improved ESP performance and lower dust emission 2. Increased gypsum purity

3. Higher SO3 removal performance 4. Lower ID-fan capacity and power consumption

Untreated Gas

Mechanism for Improvement of ESP Performance

Decrease of ESP Inlet Gas Temp. Decrease of Dust Electric Resistant Improve of ESP Performance

( cm)

High

A Coal

Dust Electric Resistant

B Coal
Conventional system

Treated Gas

Low

New fuel gas system 50 C 100 C 150 C 200 C

Gas Temperature

Mechanism for SO3 Removal

Heat Recovery Section Reheat Section GGH ESP

Adsorption of SO3 into the dust The fall of Temp. (By GGH)
Heat Transfer Medium Recirculation Pump

SO3(Vapor)

SO3(humid)

SO3 Adsorption Ash particle

Removal of SO3 Removal of SO3 with Dust

Reduction of corrosion condition Prevention of the Blue Plume

Acid dew point

Applications

DESOX

Applications

Environmental Control Systemfor Thermal Power Plants

Soma Kyodo Power Co., Ltd. (Japan) Shinchi Power Station, No. 1
Boiler Fuel: Size: Gas Capacity: Conc. of Inlet SO2: SO2 Removal Ef ciency: Absorber Type: Absorption System: Gas Reheating System: Placed in Operation: Coal 1,000 MW 3,040,400 m N/h
3

Shikoku Electric Power Co., Inc. (Japan) Sakaide Power Station, No. 3
Boiler Fuel: Size: Gas Capacity: Conc. of Inlet SO2: SO2 Removal Ef ciency: Absorber Type: Absorption System: Gas Reheating System: Placed in Operation: Heavy Oil 450 MW 1,279,000 m3N/h 1,217 ppm 96% or more Advanced Spray Tower Dust Mixing System Regenerative Type Gas-Gas Heater Mar., 2003

920 ppm 90% or more Advanced Spray Tower Dust Separation System Non-Leak Gas-Gas Heater Jun., 1994

Elektrownia Kozienice S.A. (Poland) Kozienice Power Station, No. 4 to 8

Boiler Fuel: Size: Gas Capacity: Conc. of Inlet SO2: SO2 Removal Ef ciency: Absorber Type: Absorption System: Gas Reheating System: Placed in Operation: Coal 800 MW or equivalent 3,480,000 m3N/h 1,120 ppm 93.75% or more Advanced Spray Tower Dust Mixing System Wet Stack (No Reheating) Dec., 2006

Hokkaido Electric Power Co., Inc. (Japan) Shiriuchi Power Station, No. 2
Boiler Fuel: Size: Gas Capacity: Conc. of Inlet SO2: SO2 Removal Ef ciency: Absorber Type: Absorption System: Gas Reheating System: Placed in Operation: Orimulsion 350MW 1,071,000 m3N/h 2,465 ppm 94% or more Advanced Spray Tower Dust Mixing System Regenerative Type Gas-Gas Heater Sep., 1997

Hydro Electrical del cantabrico S.A. (Spain) Abono Power Station, No. 2
Boiler Fuel: Size: Gas Capacity: Conc. of Inlet SO2: SO2 Removal Ef ciency: Absorber Type: Absorption System: Gas Reheating System: Placed in Operation: Coal 556 MW 2,362,604 m N/h
3

Tosoh Corporation (Japan) Nanyo, No. 6

Boiler Fuel: Size: Gas Capacity: Conc. of Inlet SO2: SO2 Removal Ef ciency: FGD Con guration: Absorber Type: Absorption System: Gas Reheating System: Placed in Operation: Coal 220 MW 882,400 m3N/h 840 ppm 98.3% or more New Flue Gas Treatment System Advanced Spray Tower Dust Mixing System Non-Leakage Gas-Gas Heater Apr., 2008

736 ppm 95% or more Advanced Spray Tower Dust Mixing System Regenerative Type Gas-Gas Heater Oct., 2007

DENOX
NOx Removal Systems
In the 1960s, when air pollution emerged as a major global concern, BHK started research and development for the reduction of NOx emissions from power plants. BHK rst developed a pellet type DENOx catalyst. Based upon this original catalyst, BHK developed a low-pressure drop plate type catalyst, which is presently one of our major products. Contributing to global environmental preservation, the DENOx catalysts have been adopted throughout the world, North America, Europe and Asia, as well as in Japan, and have maintained an excellent reputation for high performance.

Environmental Control Systemfor Thermal Power Plants

Basic Principle of NOx Removal

The basic principle of DENOx is simple. Ammonia is injected into the ue gas and NOx is decomposed into N2 and H2O vapor. The DENOx catalyst ef ciently facilitates ammonia and NOx reactions. The process forms no harmful by-products. Also plants using the DENOx catalyst are easy to maintain and are capable of stable operation.
Gas
N2 H2O N2 H2O N2 H2O

H2O N2

NOx

NH3 NH3 NH3 NOx NOx

NH3

Chemical Reactions of DENOx

4NO + 4NH3 + O2 6NO2 + 8NH3 4N2 + 6H2O 7N2 + 12H2O

NOx NOx NOx NOx

Tokyo Electric Power Co., Inc. (Japan) Hitachinaka Power Station, No. 1 Unit
Boiler Fuel: Size: Gas Capacity: Conc. of Inlet NO2: NOx Removal Ef ciency: Placed in Operation: Coal 1,000 MW 3,280,000 m3N/h 225 ppm 85% or more Dec., 2003

Applications of the DENOx System

Conventional Boiler Application
Gas

Seminole Electric Cooperative, Inc. (USA) Seminole Generating Station, Units No.1 & No.2
Boiler Fuel: Size: Gas Capacity: Conc. of Inlet NOx: Placed in Operation: Coal 650 MW 2,238,000 m3N/h 306.5 ppm Spring, 2009

BHK DENOx catalyst has been applied to many types of boilers, HRSGs and heaters that use various fuels. In particular, BHK DENOx catalyst has gained a superb reputation in the eld of coal- red boilers. Very low plugging potential and extremely high erosion resistance are some of the reasons for this reputation. An additional unique feature of the BHK catalyst is the adjustable plate size that enables the product to t any ue size.

NOx Removal Ef ciency: 90.3% or more

Ammonia

Air

DENOX
Catalyst Manufacturing
All of BHK DENOx catalysts are produced in its own manufacturing facility, currently in Akitsu, Japan. Over the past 40 years, the manufacturing has been continuously improved as a result of ongoing research into the product to increase its effectiveness. The present high quality, high performance and highly competitive DENOx catalyst is the culmination of four (4) decades of experience and continuous development.
Gas Gas Dust Hg Hg (Oxide)

Environmental Control Systemfor Thermal Power Plants

Function of SCR catalyst in Hg Removal Process

SCR catalyst is a key component for Hg removal process. Elemental Hg in boiler ue gas is oxidized on SCR catalyst and the most of Oxidized Hg can be removed by FGD.
Boiler Hg in Coal DENOx A/H ESP or BAG IDF DESOx Stack

High Erosion Resistance

The center metal of BHK's plate type DENOx catalyst contributes to the catalyst's high erosion resistance against the dust in gases. The substrate does not wear away allowing gas straightening to stop erosion. Homogeneous catalysts continuously wear away.

Dust

Spray Hg (Oxide)

SCR Catalyst
Ash Particulate Particulate Hg Catalyst Center Metal Plate Plate Type Catalyst Catalyst

Absorption

Hg
Elemental Hg
Solid Material Catalyst

Oxidized Hg (HgCI2)

Photos of Plate-Type Catalyst

The photos show the gas entrance edges of a plate type catalyst installed in a high dust concentration of a coal- red boiler. Even after 50,000 hours of operation, the catalyst shows negligible erosion and, although no soot blowing equipment is employed, the catalyst layer is clean.

TRACTM
Hitachi is providing Triple Action Catalyst (TRAC) having high mercury oxidation, high NOx removal and low SO2 to SO3 oxidation rate.
Before operation After 50,000 hours operation

Compact Reactor with Multi-Catalyst Stacking

BHKs plate type DENOx catalyst allows multi-layer stacking, which makes the reactor more compact at the same catalyst volume.

Hg Oxidation
Space for Added Catalyst

Conventional TRAC

Reactor

SO2 to SO3 Oxidtion

Catalyst Block (1-stage Model) Compact reactor using stacked plate type catalyst (5-stage Model) Multistage reactor

NOx Removal
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Activity ratio (-)

Our Record Speaks for Itself

DENOX

Applications

Environmental Control Systemfor Thermal Power Plants

Electric Power Development Co., Ltd. (Japan) Matsuura Power Station, No. 1 Unit
Boiler Fuel: Size: Gas Capacity: Conc. of Inlet NOx: NOx Removal Ef ciency: Placed in Operation: Coal 1,000 MW 3,029,000 m3N/h 250 ppm 80% or more Jun., 1990

Zhejiang Guohua Zheneng Power Generation Co., Ltd. (China) Ninghai Power Plant, No.4 Unit
Boiler Fuel: Size: Gas Capacity: Conc. of Inlet NOx: NOx Removal Ef ciency: Placed in Operation: Coal 600 MW 1,924,795 m3N/h 250 ppm 80% or more Nov., 2006

Kraftwerk Mehrum (Germany) Mehrum Power Station, No. 3 Unit

Boiler Fuel: Size: Gas Capacity: Conc. of Inlet NOx: NOx Removal Ef ciency: Placed in Operation: Coal 700 MW 2,240,000 m3N/h 390 ppm (6% O2) 75% or more Feb., 1989

Minnesota Power (USA) Boswell Energy Center Unit 3

Boiler Fuel: Size: Gas Capacity: Conc. of Inlet NOx: NOx Removal Ef ciency: Placed in Operation: Coal 355 MW 1,250,500 m3N/h 370.6 ppm 90% or more Nov., 2009

LG&E Energy (USA) Trimble County Generation Station, No. 2 Unit

Boiler Fuel: Size: Gas Capacity: NOx Removal Ef ciency: Placed in Operation: Coal 750 MW 2,325,600 m3N/h 80% or more Dec., 2009

Tokyo Electric Power Co., Inc. (Japan) Futtsu Power Station, No. 3 Unit
Gas Turbine Type: Fuel: Size: Gas Capacity: Conc. of Inlet NOx: NOx Removal Ef ciency: Placed in Operation: GE Frame 9 FA++ LNG 380 MW 1,870,000 m3N/h 45 ppm (16% O2) 90% Jul., 2001

CCS
CO2 Capture Systems
In the 1990s, when aimed call for protection of global warming, BHK, being ahead of the times, started research & development for CO2 capture technology. In the development of tchnology and continuous investment through pilot plant test treating actual ue gas from power plant, BHK created advanced CO2 capture system utilizing his originated solvent as amine basis (H3 series solution). Also BHK has been developing oxyfuel system simultaneously. BHK de nitely contributes to global protection as a leading player of CO2 capture technology.

Environmental Control Systemfor Thermal Power Plants

Basic Principle & System Flow

BHKs CCS system is based on amine solvent to absorb CO2, in which utilize his own developed solvent in sophisticated process. The process mainly consists of the followings. 1. CO2 absorption into capture solution from the ue gas through the packed bed in absorber 2. CO2 recovery from solvent in desorber by contacting with steam 3. Recirculation of solvent from desorber to absorber after CO2 recovery

CCS System Flow

Boiler DENOx ESP DESOx Stack CO2 Recovery

CCS Pilot Plant Test Facility in Power Station Tokyo Electric Power Co., Inc. (Japan)
Boiler Fuel: Fuel Gas Volume:
Desorber Absorber

COM (Coal and Oil Mixture) 1,000 Nm3/h 90% 4.5 ton/day Dec. 1999 Mar. 1995

Absorber

Desorber
Steam

CO2 Removal: CO2 Recovery: Pilot Plant Test Period:

Chemical Principle
Exothermic + R-NH2 + CO2 + H2O R-NH3 + HCO3 Endothermic (Solution)

Reboiler Solvent

CCS Demonstration Plant

Boiler Fuel: Fuel Gas Volume: CO2 Removal: CO2 Recovery:
Reclaimer Reboiler

Feature of BHK Process

BHK advanced Process contains several advantages which make it possible to offer more bene cial proposals due to; 1. Improvement of solvent, lower CO2 recovery heat, lower degradation rate, lower entrained solution 2. Optimum tower design, idealized packed bed, tower dimension 3. Low utility plant optimization as comprehensive design including turbine, boiler and AQCS They achieve lower energy & chemical consumptions and obtain idealized systems, as of leading technology of CO2 capture systems.

Coal 50,000 Nm3/h (Equivalent to 15 MW) 90% 300 ton/day

Akihabara UDX Bldg.10F, 4-14-1 Sotokanda, Chiyoda-ku, Tokyo 101-0021, Japan Tel : +81-3-5209-7314 Fax: +81-3-5209-7763 www.bhk.co.jp
Printed in Japan (HB) 01.2011

Babcock-Hitachi K.K.