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FLUE GAS DESULHURIZATIONFLUE GAS DESULHURIZATION

Experiences, Challenges and Opportunities

OVERVIEW OF THE MAIN TOPICS

1. EPE activities on air pollution control and flue gas cleaning

2. Experiences in the application of FGD technologiestechnologies

3. Possibilities for EPE participation in FGD projects in Serbia and in the region

ACTIVITIES ON AIR QUALITY CONTROL AND FLUE GAS CLEANING IN COAL FIRED

THERMAL POWER PLANTS

Current projects (after adoption of ELVs)

Previous projects�High stacks enabling dispersion of pollutants and air

immisions control�Flue gas dust removal using ESP –efficiency up to 98-99 %

Current projects (after adoption of ELVs)� Flue gas dust removal using high efficiency ESP – up to

99,93 %� NOx emission reduction by application of primary

measures during the major boiler overhaul – low-NOx burners and OFA system, as well as NCSR using urea solution as reagent

�� SOSO22 emission reduction by application emission reduction by application flue gas flue gas desulphurization processdesulphurization process

BRIEF HISTORICAL REVIEW OFEPE ACTIVITIES IN SO2 REMOVAL

�� During During middle 19middle 1980s80s:

♦♦♦♦ TPP Kolubara B design: Analyses of possible FGD technologies to be implemented for the purpose of required area estimation

♦♦♦♦ General study on application of FGD technologies on TPPs in EPS

�� During During 191990s90s:

♦♦♦♦ TPP Kolubara B design: Selection of referent FGD technology for ♦♦♦♦ TPP Kolubara B design: Selection of referent FGD technology for TPPs in EPS in general and general design preparation based on wet limestone/gypsym process

�� During 2000sDuring 2000s:

♦♦♦♦ Implementation of FGD process in TENT A1&A2 reconstructionproject - general design

♦♦♦♦ Study on optimization of SO2 reduction in coal fired TPPs of EPS

♦♦♦♦ Participation in PFS and FS for FGD Plant at TPP Kostolac B (with general design and basuc design)

THE MAIN RESULTS AND BENEFITS FOR EPE

� To became familiar with FGD technologies� To follow contineously developments of the

main FGD technologies� To recognize the main companies in the

world of FGD technologies� To recognize the main companies in the

world of FGD technologies� To define the needs od EPS in FGD domain

and to propose optimal solutions� To make the opportunity to participate in

the future major FGD projects for EPS and in the region

PREVIOUS AND CURRENT COOPERATION WITH FGD COMPANIES

� Lurgi-Lentjes Bischoff for TPP Kolubara B -FGD Plant general design

� Mitchubishi Heavy Industries for TENT A1&A2 - FGD Plant general designA1&A2 - FGD Plant general design

� AE&E, ALSTOM and Rafako for Study on SO2

removal optimization � Worley Parsons (with AE&E) for TPP

Kostolac B - FGD Plant general and basic design

WHY IS WET LIMESTONE/GYPSUM FGD PROCESS CHOSEN AS REFERENCE FOR TPPs IN EPS?

� Suitable for coal fired in Serbian TPPs� Suitable for all unit capacities (up to 1000 MW)� Suitable for changes in SO2 removal efficiency due

to fuel quality changes� Suitable for changes of FGD Plant load without

influence on SO removal efficiency influence on SO2 removal efficiency � Great operation experience and continual

development of process performance � Decrease both in investment as well as in

maintenance and operational expenses� Small influence on the main power plant

technology� Possible sale of by-product

PERCENT SHARE OF FGD TECHNOLOGIES

5060708090

Wet

01020304050

U S A Other World

WetDryOther

STUDY ON OPTIMIZATION OF SO2 REDUCTION IN COAL FIRED TPPs IN EPS

� Evaluation of general layouts of FGD Plants foreach coal fired TPP in Serbia

� Evaluation of the needs of limestone (quantitiesand quality) and possibilities of supply fromdomestic resources

� Evaluation of investment costs� Evaluation of investment costs� Evaluation of O&M costs� Influence on the electrcity cost, �c/kWh,

�c/kgSO2 removed� Ranking of TPPs by priority of FGD Plants

installation

THE MAIN RESULTS AND BENEFITS FOR EPS

PARAMETERS FOR FGD PLANT TECHNICAL SOLUTION SELECTION

� Unit(s) capacity and age

� Expected range of flue gas flow rate

� Expected range of input SO2 concentrations� Expected range of input SO2 concentrations

� Existing way of flue gas discharge

� Available space within TPP site, including planned TPP systems upgradings and/or changes

COAL CHARACTERISTICS

Characteristic Unit

Thermal power plant

Nikola Tesla A i B Kolubara A Kostolac A i B Morava

Mean coal

quality

Lower coal

quality

Mean coal

quality

Lower coal

quality

Mean coal

quality

Lower coal

quality

Mean coal

quality

Lower coal

quality

Low heat value kJ/kg 6.608 6.018 8.100 7.200 7.648 6.285 8.000 7.200

Dust % 18,5 26,9 10,00 12,00 23,7 28,0 14,3 12,00

Moisture % 49,2 44,5 51,8 50,5 40,3 40,2 49,0 51,8Moisture % 49,2 44,5 51,8 50,5 40,3 40,2 49,0 51,8

Volatile % 20,1 18,2 23,2 22,4 - - 22,5 23,2

Total sulphur % 0,42 0,47 0,45 0,45 1,13 1,08 0,62 0,45

Sulphur emission rate 0,9 0,9 0,9 0,9 0,9 0,9 0,9 0,9

Carbon % 19,8 18,2 24,1 22,15 22,1 19,3 23,7 22,1

Oxygen % 9,6 7,4 10,2 10,2 8,9 8,4 10,0 10,2

Hydrogen % 2,1 2,0 2,3 2,1 2,1 1,9 2,1 2,1

Nitrogen % 0,6 0, 7 1,2 1,2 0,8 0,8 0,5 1,2

THERMAL POWER PLANTS FLUE GAS CHARACTERISTICS

ParametarThermal power plant

Nikola Tesla Kolubara A Morava Kostolac

SO2 concentrations, mg/m3 2.750 – 3.200 2.390 – 2.640 2.640 – 3.450 6.540 – 7.150

SO2 emission, kg/MWh 11,6 – 15,3 12,2 – 17,1 12,3 – 15,5 26,7 – 37,9

SO2 emission, kg/kJ 1,2 – 1,4 1,0 – 1,1 1,1 – 1,4 2,7 – 3,1

Flue gas flow, m3/kWh 8,9 – 9,9 10,4 – 14,1 9,0 – 9,6 9,3 – 10,7

Moisture content, % 23,6 – 24,2 22,0 – 23,2 21,4 – 23,2 19,9 – 21,5

Dust content, mg/m3∗∗∗∗ 50 200 – 400 800 50

Chlorine content, mg/m3∗∗∗∗ 20-60 20-60 20-60 15-60

∗ dry gas, 0°C, 1013 mbar, 6% O2

FGD DESIGN CONSIDERATION FOR LIGNITE COAL

� Large flue gas volume� High SO2 content & high removal efficiency� High fly ash loading� High fly ash loading� High inlet gas temperature� High inlet gas moisture

FGD PLANT - TECHNICAL SOLUTION OPTIONS

� Limestone delivery (powder or crashed limestone)

� By-product handling (usage or disposal)� By-product handling (usage or disposal)� Flue gas discharge (wet or dry stack) � Pressure drop solution

MAIN QUESTIONS TO BE DEFINEDBEFORE FINAL DEFINITION OF

FGD PLANT TECHNICAL SOLUTION

� Referent fuel characteristics� Operation span for Units A1&A2� Available space in relation to ash and slag

collection and transport system (new collection and transport system (new “thick” slurry system)

� Possibilities for commertial use of gypsumand requirements for gypsum quality

� Requirements for limestone quality and possible resources

"EUROGYPSUM SPECIFICATION"QUALITY STANDARDS

For the Product FGD Gypsum

QUALITY PARAMETERS FORMULA UNITQUALITY STANDARDS

Free moisture % by weight < 10

Calcium sulphate dihydrate CaSO4 x 2H2O % by weight > 95

Magnesium oxide water soluble MgO % by weight < 0,10

Sodium oxide Na2O % by weight < 0,06

Chloride CI % by weight < 0,01

Sulphur dioxide SO2 % by weight < 0,25

pH 5 - 9

Colour White

Odour Neutral

Toxicity Non-toxic

DESIGN LIMESTONE QUALITY REQUIREMENTS

Parameter Units Reporting Basis

Case 1, Disposable

Gypsum

Case 2,Wallboard Gypsum

Free Moisture Weight % As received �5,0 �5,0

Calcium Carbonate, Total as CaCO3

Weight % Dry �89,0 �94,0

Magnesium Carbonate, Weight % Dry �4,0 �,30Magnesium Carbonate, Total as MgCO3

Weight % Dry �4,0 �,30

Silicon Dioxide – as SiO2

Weight % Dry �5,0 �3,0

Iron Oxide – as Fe2O3 Weight % Dry ------ �0,8

Total Inerts (Including MgCO3)

Weight % Dry �,11,0 �6,0

Particle Size Analysis Millimeter Dry 19,05××××0 19,05××××0

Bond Work Index (BWI) KWh/T As received �10,8 �10,8

CHALLENGES AND OPPORTUNITIES FOR EP & SERBIAN INDUSTRY

� Consulting services in Project development� Participation in design of FGD subsystems, both

mechanical and electrical, such as♦♦♦♦ limestone handling and slurry preparation♦♦♦♦ gypsum slurry transport and disposal or

gypsum handlinggypsum handling♦♦♦♦ waste water treatment

� Civil design� Manufacturing of equipment, both mechanical

and electrical (except special parts and systems)� Execution of civil works� Assembling of mechanical and electrical

equipment (except special works on absorber)

THANK YOU FOR YOUR KIND ATTENTIONKIND ATTENTION