WEL – COME

Presentation on FGD

Presentation on
Flue Gas De-Sulphurisation (FGD) System

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Presentation on FGD
Introduction :

 Coal is the most available fuel for the electricity generation in our country. Abundant
supply of coal locally and sustained high prices for imported natural gas and oil make
coal-fired generation of electricity more attractive economically.

 Relatively lower calorific value, coupled with high ash content and inefficient
combustion aggravate emission of greenhouse gases and other pollutants from India’s
coal based thermal power plants.

 Main emissions from coal fired thermal power plants are CO2, NOx, SOx, Air-borne
inorganic particles such as fly ash, carbonaceous material (soot), suspended particulate
matter (SPM) etc.

 This presentation discusses control of SOx emission in Coal Fired Power Plants in India
in the light of latest MOEF Regulations

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Presentation on FGD : Sources of SOx

• The majority of sulfur

oxides come from
power generation
sources:
- coal
- oil

S + O2  SO2

Other sources include:

- other industry such as paper mills
- mobile sources
- natural sources (e.g. volcanoes)

While SO2 is the main sulfur-containing pollutant, there are various others:

• SO3 (the other “oxide”) SO2 + ½ O2  SO3

• H2S (rotten egg smell)

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Presentation on FGD : Effects
HUMAN HEALTH EFFECTS:

• Lung and throat irritation

• Worse symptoms for those with bronchitis
• Weakening of the immune system

Sulfur oxides in combination with other air pollutants seem affect health even
more:
1) SOx with acid aerosols can product chronic cough and difficulty breathing
2) SOx with PM has produced some of the worst air pollution disasters (London
1952)
EFFECTS ON PLANTS:

• Sulfur dioxide can enter leaf stomata, causing:

1) Necrosis – morphological changes due to cell death (produce brown / black spots)
2) Chlorosis – “bleaching” of leaves, producing a yellow or white discoloration

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Presentation on FGD
Basic Principles:

 When fossil fuels are burnt, about 95% of the sulphur is generally converted
to Sulphur Di-oxide (SO2) generally called as SOx.

 When flue gas has too much oxygen, the SO2 further oxidizes into Sulphur-Tri- Oxide

(SO3)

 It forms a liquid aerosol called Sulphuric Acid mist ( H2SO4) which is hard to remove.

 A blue haze that would often appear as the flue gas plume dissipates through
chimney.

 Flue-gas desulphurization (FGD) is essentially used to remove Sulphur Dioxide

(SO2) from the exhaust flue gases of fossil fuel power plants.

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Thermal Power Plants in India

Western
18.39%
Northern
39.97%
17.23% Eastern

Southern
24.41%

Break up Statistics:

State &
Total Total Central State Private Power
Central
Region Thermal Units in Govt. Govt. Sector Generation
Joint
Plant Plants Plants Plants Plants (MW)
Plant

Western 41 140 4 23 14 - 67029.01

Northern 27 104 7 17 3 - 40943.50
Eastern 36 104 13 13 10 - 28892.87
Southern 28 83 4 12 10 2 30842.50
Total 132 431 28 65 37 2 167707.88

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Thermal Power Plants of MSPGCL
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210 MW Units
8
250 MW Units

19 500 MW Units

660 MW Units
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No. of
Sr. Capacity of Units (MW) Total capacity
units
1 210 MW Units 19 3990
2 250 MW Units 5 1250
3 500 MW Units 8 4000
4 660 MW Units 3 1980
    35 11220

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FGD : MANDATORY REQUIREMENT

 MoEF vide their notification dated 07.12.2015 has also imposed the condition of
reduction of SOx level less than 200mg/Nm3 for units having capacity 500MW and
above.
 Total approximate amount required to install FGD and to meet the environmental
norms for SOx Estimated expenditure calculated on the basis of budgetary offer of Rs.
50 Lakhs / MW
 For all Thermal Units in India : 83,854.00 Crore
 For all Thermal Units of MSPGCL : 5,610.00 Crore
Sr. Capacity of No. of Approximate
Units Units Expenditure In Cr
1. 660 MW 3 990
2. 500 MW 8 2000
3. 250 MW 5 625
4. 210 MW 19 1995
Total 35 5610
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FGD : Present Level of SOx of 10 MSPGCL Units
(Sample Data)

Sr. Unit SOx Level NOx Level

mg/Nm3 mg/Nm3
1. Chandrapur Unit-6 500MW 1182 --
2. Chandrapur Unit-7 500MW 1238 --
3. Khaparkheda Unit-1 210MW 706 119
4. Khaparkheda Unit-2 210MW 729 123
5. Khaparkheda Unit-3 210MW 693 115
6. Khaparkheda Unit-4 210MW 674 113
7. Khaparkheda Unit-5 500MW 993 119
8. Bhusawal Unit-3 210MW 823 133
9. Bhusawal Unit-4 500MW 1370 133
10. Bhusawal Unit-5 500MW 1365 133

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FGD : VARIOUS TYPES

FGD

WET SCRUBBING DRY SCRUBBING

LIMESTONE F SEAWATER S SEMI DRY SC CIRCULATING

ORCED OXID CRUBBING RUBBING DRY SCRUBB
ATION ER

GYPSUM NONE SULPHITE SULPHITE

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FGD : CHALLENGE – SELECTION OF FGD TECHNOLOGY

Selecting the right FGD technology is a challenge.

Techno commercial aspects to be considered

Techno commercial aspects

Technical Commercial
- Competent vendor with
- Sulphur removal efficiency proven
- Operational and performance track record
reliability - Performance Guarantees
- Space Constraints - Capital Cost
- Operational Cost

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FGD : FINANCIAL ASSISTANCE & IMPACT ON TARIFF
Sr. WFGD DFGD

1 SO2 removal – can achieve 98% 94%- 98%. requires high stoichiometry to achieve >94%

2 Can handle wide range of sulphur Comparatively less

3 Needs more foot print Comparatively less

4 Scalability of capacity – can be adopted for wide Limitation to handle large flue gas volumes. Limited up
range of capacity – large plants of 1000MW to say 300MW

5 WFGD can generate liquid waste which is to be Generates solid waste

treated
6 Generates by product gypsum Predominantly calcium sulfite solid is formed which is of
( Not applicable to SWFGD) little practical value

7 Water consumption – High compared to DFGD Low compared to WFGD

8 Auxiliary power – more compared to DFGD Less compared to WFGD ( approx. 0.7%)
(approx. 1.2 to 1.5%)

9. Wet FGD = X Then Sea water FGD = 0.8X Dry FGD = 0.7 X

10 No need for Fabric Filters Fabric Filters required

11 Overall Life cycle cost is less for large capacity Can be cost effective for smaller capacity plants up to
plants 250-300MW

Many technologies are available today for efficient removal of SO 2. Due diligence study to be done to
select the techno commercially suitable technology to be adopted specific to plants. 1
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FGD SYSTEMS IN INDIA

Sr. Name of Owner / Location Capacity of Type of FGD

Organisation Unit
1. Tata Power Trombay 500 MW SW-FGD
(Maharashtra)
2. Reliance Industries Ltd. Dahanu 2 x 250 MW SW-FGD
(Maharashtra)
3. Lanco Udipi 2 x 250 MW WET - FGD
(Karnataka)
4. JSW Ratnagiri 300 MW SW-FGD

5. NTPC Bongaigaon 3 x 250 MW WET - FGD

6. NTPC Vindhyachal 500 MW WET - FGD

(Madhya
Pradesh
7. Adani Power Mundra Phase-III TPP SW-FGD
(Gujrat)
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FGD SYSTEM : Challenges ahead of MSPGCL

Sr. Activity Qty Required Approx. Remarks

Amount
1. Water requirement 2400m3/ Day --- Water requirement will increase.
for each Unit
2. Enhancement of 1200 m3 /day --- Feasibility of existing ETP
existing ETP for each unit capacity to cater the additional
capacity load of effluent due to FGD.

3. Lime Stone 12.50 Lakh MT / Rs. 68.75 Presently Lime stone Production
requirement Year for all plant Crores of India during 2013-2014 is 278
(Considering Sulphur of Mahagenco (Considering Mn. Tonne/ Year
% as 0.48%) (Approx = 1.25 Limestone rate
Mn. Tonne) of Rs. 550 / MT)

4. Disposal of Gysum 20.75 Lakh -- MSPGCL has to find out potential

( Considering Sulphur MT / Year buyer who can absorb such huge
% as 0.48%) (Approx = 2.08 qty of gypsum produced. Cement
Mn. Tonne) Industries are in need of 20 Mn.
Tonne of gypsum presently (2016).

5. Space Constraint 100 M x 200M -- MSPGCL units like Koradi,

for FGD Chandrapur-8,9 & Parli-8 where
space is available for FGD. In
rest of the units space is not
available.
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FGD : FEED BACK OF VISIT TO NTPC VINDHAYCHAL

P&P team has visited NTPC Vindhyachal plant 0n 07.06.2016. The highlights are as
under ------
NTPC Vindhyachal has total 13 Units –
6 x 210 MW : 1260 MW
7 x 500 MW : 3500 M
Wet FGD is being provided in Unit-13 of 500 MW capacity.
 Agency : M/s. Alstom ( Now Known as M/s.GE)
 Cost : Rs. 202.56 Crores
 Order Placed in Year 2012.
 Period of execution : 30 months but work is in progress 70% work completed in
last 36 months. Civil & mechanical work is nearly completed. Electrical, Control &
Instrumentation work is balance. Expected commissioning of FGD @ Jan-2017.
 Foot Print requirement : 100M x 200 M ( Koradi Space 71M x 375M)
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FGD System requirement : Lime Stone availability in India

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FGD System requirement : Lime Stone Reserves in India

LIMESTONE RESERVES IN INDIA

Total Limestone Reserves are estimated at 110,907 million tons

Zone - Wise Reserves: Mn. Tons

North
(Haryana, H.P.J&K, Rajasthan, Uttarakhand, U.P) 34,775

East
(Assam, Manipur, Meghalaya, Arunachal, Orissa, W.B.,
Jharkhand, Nagaland) 9,571

West
(Chhattisgarh, Gujarat, M.P., Maharashtra, Diu) 20541

South
(A.P., Karnataka, Kerala, Tamilnadu, Andaman,
Lakshdweep) 46,019

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FGD System : Lime Stone Production State-wise in India P&P - BTG

70

60

50

40

30

20

10

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

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FGD System : Lime Stone production State-wise in India P&P - BTG

State Unit 2011-2012 2012-2013 2013-2014

Andhra Pradesh Mn. Tonne 54.602 63.438 59.354
Assam Mn Tonne 0.248 0.384 0.198
Bihar Mn Tonne 0.507 0.588 0.514
Chhattisgarh Mn Tonne 20.465 20.172 21.061
Gujarat Mn Tonne 24.098 26.071 23.279
Himachal Pradesh Mn Tonne 10.801 13.104 11.576
Jammu & Kashmir Mn Tonne 0.225 0.192 0.215
Jharkhand Mn Tonne 2.48 1.861 1.902
Karnataka Mn Tonne 20.276 21.132 21.47
Kerala Mn Tonne 0.539 0.488 0.501
Meghalaya Mn Tonne 4.216 4.032 3.599
Madhya Pradesh Mn Tonne 34.072 35.536 36.917
Maharashtra Mn Tonne 12.281 11.924 10.877
Orissa Mn Tonne 3.136 3.912 3.827
Rajasthan Mn Tonne 47.982 52.54 56.328
Tamil Nadu Mn Tonne 23.643 26.442 23.963
Uttar Pradesh Mn Tonne 2.997 3.214 3.144
India Mn Tonne 262.568 285.03 278.725 19
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FGD System : Gypsum Requirement & Use
USES OF GYPSUM :
1) Cement Industry
2) Wallboard Manufacturing
3) Agriculture – Soil Conditioning
4) Plaster of Paris

SOURCES OF GYPSUM FOR CEMENT INDUSTRIES :

1) Natural Gypsum available in Rajasthan & Gujarat in India
2) Bi-Product Gypsum from Industrial houses in India
3) Imported Natural Gypsum mainly from Thailand & Iran

REQUIREMENT OF GYPSUM BY CEMENT INDUSTRIES :

• India’s production capacity by the end of 2017 shall be about 479 million tonnes
per annum
• 4 to 5 % gypsum is required as raw material for production of cement. i.e.
@ 24 million tonnes.

PROBLEMS FACED BY THE CEMENT INDUSTRY :

Depletion of Natural Gypsum Reserves in India
Restricted Export of gypsum by Thailand – By quota & price control mechanism
Local production/availability in India is limited to about 6-7 million tonnes per annum 20
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Highlights of MOEF’s New Standards specific to emission norms

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FGD System - Wet Scrubbing using Limestone

• Sulphur Dioxide (SO2) is an Acid

Gas
• Scrubbers used to remove SO2
are typically Alkaline
• Process using Limestone
• SO2 Absorption
• Limestone
(CaCO3)Dissolution
• Forced Oxidation
• CaSO4 Precipitation

•Overall Chemistry
SO2+CaCO3+O2+H2O

•CaSO4.2H2O + CO2

GYPSUM
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Seawater Flue Gas Desulphurization

• Sea water contains significant

amounts of HCO3- that help SO2
in flue gas dissolve in water.
• Sea water is sprayed through
nozzles in a scrubber ( counter
current)
• The scrubbed water is taken to
aeration tank and alkali is dosed
to rise the pH
• Process using Seawater
• Absorption
• SO2+H2O SO32-+ 2H+
• Neutralization
• H++ HCO32_ CO2 +H2O
• Oxidation
• SO32-+1/2O2 SO42-

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FGD System (Semi Dry Process) – Spray Dryer Absorber

• Quick Lime (CaO) and Hydrated

Lime ( Ca(OH)2) are the reagents
• SO2 removal process is upstream
of ESP

•Overall Chemistry
CaO+H2O Ca(OH)2
Ca(OH)2+SO2 CaSO3. 1/2H2O
Ca(OH)2+SO2 CaSO4. 2H2O

• Significantly more calcium

sulphite is formed than Calcium
sulphate in this process

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FGD System : Circulating Dry Scrubber (CDS)

• Dry process normally producing

dry free flowing disposal
product
• Flue gas is directed to CDS for
scrubbing acid gas
• Hydrated Lime Ca(OH)2 is
introduced in the scrubber as a
free flowing powder
• Lime utilisation is improved by
evaporative cooling of flue gas
by water and also recirculation
of Calcium
• SO2 removal of 98% can be
achieved by this process
• Arrangement required small
foot print. Advantage for
retrofit projects with space
constraints
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THANK YOU

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