VGB PowerTech 5 l 2016

Circulating fluidised bed scrubber vs. spray dryer absorberMulti-pollutant control technology
assessment: Circulating fluidised bed
scrubber vs. spray dryer absorber
Matthew Fischer and Greg Darling
Kurzfassung

Introduction

Minderung von Multi-Emissionen:
zirkulierender Wirbelschichtwäscheroder Sprühtrocknungsabsorber?

The converging US Environmental Protection Agency (EPA) rules for reducing mercury, metals, acid gases and organic compounds (Mercury and Air Toxics Standards
or MATS), Regional Haze (RH) and SO2,
NOx as well as particulates (Cross-State Air
Pollution Rule or CSAPR) have ratcheted
up the pressure on coal-fired generators toquickly reduce a variety of pollutants. The
EPA estimates that CSAPR alone requires
more than 3,000 units at more than 1,000
plants located in 28 states to reduce emissions that cross state lines and contributeto ground-level ozone and fine particle pollution. CSPAR Phase 1 compliance takes effect this year while MATS and RH reduction are ongoing programmes.

Strengere Auflagen zur Minderung von Emissionen setzen Kraftwerksbetreiber zunehmend
unter Druck. Kohlebefeuerte Anlagen sinddaher mit Rauchgasentschwefelungsanlagen(REA) nachzurüsten. Am Markt gibt es zahlreiche Systeme zur gleichzeitigen Minderung einer
Reihe von Emissionen (Multi-pollutant control). Derartige Systeme sind einer klassischen
REA bei weitem überlegen.
In vorliegenden Beitrag werden die Unterschiede zwischen modernen Wirbelschichtwäschern
und fortschrittlichen Sprühabsorptionstrocknern dargestellt. lVGB PowerTech - Autorenexemplar - © 2015

The debate over what limits will be imposed has now shifted to how individual
units will comply with the prescribeddeadlines. There are as many technical approaches to meeting new emission limits as
there are differences in plant designs. Adding to the complexity of any solution is theuncertainty of future rules that will require
further reductions of an expanding rangeof pollutants.

Authors
Matthew Fischer
Product Leader – Dry FGD Systems
Greg Darling
Product Leader – CFBS Systems
Amec Foster Wheeler
Pittsburgh, Pennsylvania, USA

In the past, SO2 capture on a large scale
was the province of wet flue gas desulphurisation (WFGD) technology. It has theadvantage of relatively low operating costand uses readily available limestone as thereagent, which can be recycled into a number of useful products to offset operating
costs. However, WFGD scrubbers do havedisadvantages, such as large capital andhigh maintenance costs. By design, many
WFGD systems require periodic dischargeof the scrubber liquor to maintain solids
and/or chlorides. This effluent requires additional treatment which adds capital andoperating costs. Also the uncertainty of
future regulations, specifically the SteamElectric Power Generating Effluent Limitation Guidelines (ELG), may require additional discharge treatment.
WFGD is also limited in its ability to capture mercury and SO3. Some plants havereported increased mercury removal as adesirable, but expensive co-benefit when aselective catalytic reduction (SCR) system
for NOx removal was installed upstream of
the WFGD scrubber. Other plants have also>>> VGB DIGITAL <<<added injection of one or more proprietary
reagents into the furnace, such as dry sorbent injection (DSI), as a means to increase
the mercury removal co-benefit. Stacking
technologies is not a cost effective longterm strategy to reduce pollutants – it isunnecessarily expensive and reduces theoverall reliability of the entire unit. A more
holistic solution is preferred.

Technology comparison
Interest in dry or semi-dry FGD scrubbers
is increasing due to its ability to capture
mercury, acid gases, dioxins, and furans,
in addition to SO2 and particulates. These
multi-pollutant technologies also haveadded benefits: no liquid discharge andsignificantly reduced water consumption,
which is increasingly important to power
plants that are under pressure to reducewater consumption.
Two multi-pollutant technologies dominate the utility sector. The fundamental
difference between the two technologies is
the manner in which the reagent is mixed
with the incoming flue gas to remove thedesired pollutants. The first technology
is the spray dryer absorber (SDA), whichsprays atomised lime slurry droplets into
the flue gas. Acid gases are absorbed by theatomised slurry droplets while simultaneously evaporating into a solid particulate.
The flue gas and solid particulate are thendirected to a fabric filter where the solidmaterials are collected from the flue gas.
Amec Foster Wheeler has installed 60 SDA
units representing over 4,500 MW of plant
capacity. The second is the circulating fluidised bed scrubber (CFBS, which circulates boiler ash and lime between a scrubber and fabric filter). Amec Foster Wheeler
has install 78 CFB scrubber units representing over 7,000 MW of capacity in the power
and industrial industries.

Spray dryer absorber (SDA)
SDA technology operates using absorption
as the predominant collection mechanism.
In general, the acid gas dissolves into the alkaline slurry droplets and then reacts withthe alkaline material to form a filterable
solid. Intimate contact between the alkaline sorbent (hydrated lime) and flue gases
make the gas removal process effective.
57

VGB PowerTech 5 l 2016

Circulating fluidised bed scrubber vs. spray dryer absorber

Perforated distribution
plate & flow
straightenerproduce a consistent droplet size whileproviding longer nozzle life. In 14 field applications, the optimised nozzle has demonstrated low cleaning frequency (1 to
3 weeks continuous operation), reduced
cost of operation (20 to 25 % less compressed air consumption) and longer life
with its new tungsten carbide inserts. In
addition no special tools are required forroutine maintenance.
The SDA design also provides additional
operating flexibility for the entire plant.
For example, any two-fluid nozzle can beremoved for maintenance without decreasing boiler load. Emission control performance is maintained even when multiple
two-fluid nozzles are taken out of service.
The SDA is also capable of high unit turndown, down to 25 % of rated flue gas flow
without recirculation of the flue gases
while maintaining emission requirements.
The design of the unit also provides for fastload response enabling unit cycling or load
following. An added advantage is low absorber pressure drop that keeps the parasitic fan power loss to a minimum.

Flue gas in

Two fluid nozzles

Reaction vessel

Two-phasereactionprocess

Circulating fluidised bed scrubber
Flue gas out

Solids discharge hopper

VGB PowerTech - Autorenexemplar - © 2015

Fig. 1. SDA design details. The SDA uses hydrated lime to treat flue gas. The heat of the flue gas
evaporates the droplets which cools the flue gas. Cooled flue gas containing the driedproducts is directed to a fabric filter. Source: Amec Foster Wheeler.

The key to efficient performance is themeans used to atomise the lime slurry into
droplets within the gas stream. The SDA
offered by Amec Foster Wheeler utilises a
two-fluid nozzle to atomise the lime slurry.
The fine spray provides increased contact
area in order for gas absorption to occur
compared to the CFBS (it is easier to mix
a gas with a liquid than with a solid). Acidgases are then absorbed onto the atomised
droplets. Evaporation of the slurry waterin the droplets occurs simultaneously withacid gas absorption. The cooled flue gas
carries the dried reaction product downstream to the fabric filter. This dried reaction product can be recycled to optimise
lime use (F i g u r e 1).
At the beginning of SDA application, industry experienced that they were expensive
to operate and maintain regardless of theatomisation mechanism used. Amec Foster
Wheeler has redesigned its two-fluid nozzle to improve the distribution and mixing
of atomising air with lime slurry, which
improves mixing efficiency and decreases
58

operating and maintenance costs (F i g u r e 2). The optimised nozzle design delivers even atomising air distribution to

Boiler flue gas enters the CFBS (with orwithout ash) at the bottom of the up-flow
vessel, flowing upward through a venturi
section that accelerates the gas flow rate,causing turbulent flow. The turbulator
wall surface of the vessel causes highly turbulent mixing of the flue gas, solids, andwater for 4 to 6 seconds to achieve a highcapture efficiency of the vapour phase acidgases and metals contained within the fluegas. The gas and solids mixture then leaves
the top of the scrubber and the fabric filter
removes the solid material. (F i g u r e s 3
and 4).
Recycled solids/hydrated lime and watermix with the turbulent flowing gas moving
vertically through the vessel, which provides gas cooling, reactivation of recycled

Tab. 1. Key technical characteristics of SDA and CFBS (Source: Amec Foster Wheeler).
Performance characteristic
Fuel sulphur content
SO2 removal %Capacity per vessel
Turndown capability,% of MCR flue gas flow
Sorbent
Sorbent treatment
Sorbent utilisation (molar Ca/S ratio)
Control flexibility

SDA

CFBS

<2.5 %<3.5 %

95 to 97 %95 to 98+ %40,000 to 1,000,000 acfm

75,000 to 1,800,000 acfm

25 % without FGR

50 % without FGR
25 % with FGR

Calcium hydroxide slurry

Dry calcium hydroxide

SlakerDry hydrator

1.4 to 1.5 (without recycle)
1.15 to 1.25 (with recycle)

1.3 to 1.4

Temperature limited

Temperature independent

Water quality

MediumLow

Capital cost

Slightly lower

Slightly higher

Larger diameter vessel,
smaller fabric filter,
equal overall footprint

Smaller diameter vessel, larger
fabric filter (lower A/C ratio),equal overall footprint

Footprint, includes fabric filter

Notes: MCR = maximum continuous rating; FGR = flue gas recirculation; acfm = actual cubic feet per minute>>> VGB DIGITAL <<<VGB PowerTech 5 l 2016

Circulating fluidised bed scrubber vs. spray dryer absorber

Lime slurry

Nozzle shroud

Atomizing air

Atomizing air

Lime slurry

Air reservoir

Shroud air

Lance assembly

Two fluid nozzle

Inserts

Fig. 2. Two-Fluid nozzles released. The optimised two-fluid nozzle design ensures balanced
atomising air distribution in order to produce a consistent droplet size and reduced compressed air consumption by a quarter. Also, tungsten carbide inserts have significantly
reduced nozzle wear. Source: Amec Foster Wheeler.

ash and capture of pollutants. The CFBS
process achieves a very high solids-to-gas
ratio, which dramatically improves theability of vapour phase pollutants to findadsorption sites on the colliding solid particles. The water plays the important roleof cooling the gas to enhance the adsorption of the vapour phase pollutants onto
the solid particles.

In general, the CFBS offers slightly greaterSO2 removal flexibility when compared to
SDA. The amount of fresh lime injection is
not limited by flue gas temperature thus allowing greater SO2 scrubbing performanceover a wider range of fuel sulphur content(F i g u r e 5). SDA systems are temperature
limited because fresh lime is introduced asslurry (lime and water). In addition, due towater being introduced independently andpurely for temperature control, the CFBS
can utilise lower quality water, as it is not
used for pebble lime hydration.
The CFBS has the ability to effectively treat
more flue gas volume than an SDA. The
multiple venturis present allow a single
CFBS vessel to be scaled up to almost twicethat of the SDA vessel option.
Turndown capability is built into the SDA
design, where a CFBS requires a flue gas
recirculation system in order to achieveequivalent turndown. An SDA utilising
the two-fluid nozzle design can maintain

Fabric filter
CFB
Scrubber

VGB PowerTech - Autorenexemplar - © 2015

The gas and solids mixture exit at the topof the scrubber and enter the fabric filter
where solids entrained in the flue gas arecaptured and recycled back to the scrubber to capture additional pollutants. A
portion of the recycled solids is removed
from the fabric filter in order to maintainthe right quantity of material in the circulating loop.
The effectiveness of the sorbent is largely a function of residence time. A CFBS
can keep solids in the system from 20 to
30 minutes. This is a sufficient period oftime for the sorbent to react with the acidgases. Two independent control systems
maintain the dry flue gas at optimum
temperature and at adequate removal efficiency by controlling the amount of water added and the amount of fresh sorbent
added separately. As a result, unlike the
SDA scrubber, pollutant capture is not limited by inlet flue gas temperature.

Circulating fluidised bed scrubber
vs. spray dryer absorberTa b l e 1 summarises the important technical differences between the SDA and
CFBS options. Ta b l e 2 shows the performance differences. In general, the CFBS is
slightly better at SO2 control, with up to98+% capture with high amounts of sulphur in the fuel. Plant turndown capability
is equivalent, when the CFBS is equippedwith flue gas recirculation.

Water
Hydrated
lime

Air
Air
Solid
by-product
Inlet flue gas
and ashReactor ash drain

Fig. 3. CFBS design details. The principal operating steps is recycling a solids/hydrated lime
and water mixture in the flue gas flow to capture pollutants, cool the gas and then capturesolids in a fabric filter. Other reactive absorbents like activated carbon can be added totarget specific pollutants. Source: FWEC.

>>> VGB DIGITAL <<<59

Circulating fluidised bed scrubber vs. spray dryer absorber

VGB PowerTech 5 l 2016

Dry flue gas
with solids

Multiple venturi design
CFB
Scrubber

Water

Hydratedlime

VGB PowerTech - Autorenexemplar - © 2015

Raw fluegas & ash

Recycled
solidsAbsorberbottomFig. 4. Turbulent mixing. Flue gas enters vertically upward into the scrubber andthrough a set of venturis that accelerate
the gas flow. Wall turbulators increase
flue gas and reagent mixing efficiency.
Multiple venturis allow a single scrubber
to be scaled up to 600 MW in unit
capacity. Source: FWEC.

Fig. 5. World’s largest CFB scrubber. The 420 MW-rated (500 MW equivalent gas flow at its
4,430 ft. site elevation) coal-fired unit at Basin Electric’s Dry Fork Station has operated theworld’s largest CFBS since it entered service in June 2011. Since it went into operation, the
CFBS has exceeded its design performance reducing SO2 by 95. to 98 % to levels below
0.06 lb/MMBtu (50 to 60 mg/m3). It also passed a 30-day mercury removal compliancetest by meeting the permitted emission limit of 20 lb/TWh (2.35 µg/m3) while demonstrating an Hg removal rate in excess of 95 %. Courtesy: Basin Electric Co-Op and Wyoming
Municipal Power Agency.

required emission levels down to approximately 25 % of MCR. In a CFBS at lower
loads additional recirculated flue gas isrequired to maintain bed velocities in order to maintain required emission levels.
If turndown during non-peak power demands is a consideration the additional
parasitic load is an operating cost consideration for the CFBS.

Both technologies are simple, reliable, androbust. When maintenance of the CFBS is
required, the accumulated solids can easily be removed through the bottom of thescrubber. Also, the water nozzles are low
maintenance and can be replaced withthe unit in operation. SDA two-fluid nozzles may also be removed and maintained
during plant operation without loss of unit
capacity. No special tools are required for
two fluid nozzle maintenance.

The CFBS provides greater sorbent utilisation compared to a once-through SDA system as reagent recycle is incorporated into
the design (F i g u r e 6). However, due tothe difference in hydration efficiency, an
SDA equipped with recycle offers greater
overall sorbent utilisation compared to
CFBS. In an SDA, the recycled solids are
slurried within a tank providing essentially
100 % hydration. In a CFBS water spraynozzles wet the dry recirculated solids as
it passes through the vessel. This hydration
process is less efficient due to the quantityof recycled solids and the lack of sufficient
wetting time.
All the other performance characteristics
are relatively equivalent including net auxiliary power. The pressure drop in the SDA(10 inches H2O) is much less than the equivalent sized CFBS (16 inches H2O), which is
proportional to ID fan power consumed.
However, the auxiliary power used by the
SDA, principally for compressed (atomising) air, exceeds that required by the CFBS.
The net result is that the total auxiliary
power used by the either option is approximately equivalent. However, depending on
the unit capacity, pressure drop may have agreater operating cost impact compared tothe additional auxiliary power of an SDA.
60

Fig. 6. World-class SDA. JEA’s Northside Generating Station includes two Amec Foster Wheeler
CFB boilers (2 x 300 MW units), each producing 831,000 ACFM of flue gas. Each boiler
uses a single SDA followed by a pulse jet fabric filter to treat the flue gas produced by the
pet coke- and coal-fired unit. SO2 emissions are reduced up to 90 % and SO3, HCl, and
HF emissions are reduced up to 99 %. Particulate emissions are 0.011 lb/MMBtu of fuelconsumed. The SDA uses CFB fly ash only; no fresh lime addition is required. The plant has
been in operation since 2002. Courtesy: Amec Foster Wheeler.

>>> VGB DIGITAL <<<VGB PowerTech 5 l 2016

Circulating fluidised bed scrubber vs. spray dryer absorber

No one size fits all technology

Tab. 2. Key performance characteristics of SDA and CFBS (Source: Amec Foster Wheeler).

In the past, dry scrubbing technology was
typically chosen over WFGD technology
for its much lower capital cost and water
usage, provided that the boiler size was
not too large and the fuel sulphur content
was not too high. Today, CFBS technology
has broken through these limitations withsingle unit designs up to 600 MW backed
by operating experience on coal-fired unitsof over 500 MW and on fuels with sulphurlevels above 4 % by weight. SDA have also
been deployed on equal-sized units butwith 2 absorbers and more limited fuel sulphur ranges.
The utility retrofit market has leaned more
toward the CFBS technology of late due tothe higher SO2 removal performance.
However, SDA are gaining popularity due
to a new generation of SDA nozzles which
has significantly reduced cleaning frequency, which was a major criticism by earlyParameter

SDA

CFBS

SO2 removal, %95 to 97 %95 to 98+ %SO3 removal, %

95+

95+

HCl/HF removal, %99

99

Total PM Removal efficiency, %

99+

99+

Mercury removal efficiency, % (with or without PAC)

Equal

Equal

Pressure drop, inches H2O

10

16

Auxiliary power consumption

HigherLower

Total power consumption (including ID fan)

Equal

Equal

Availability, %99

99

Water consumption

Equal

Equal

Noise

Equal

Equal

Notes: ID = induced draft; PAC = powdered activated carbon; PM = particulate matter

adopters. In addition the SDA offers greater
turndown capability without flue gas recirculation equipment. With extended nozzle
life and reduced compressed air consump-tion, the performance gap between the SDA
and CFBS has narrowed. Specific site andenvironmental permit requirements will belthe determining factor.

VGB-Standard

!
NEU !
NEW

Provision of Technical Documentation(Technical Plant Data, Documents)
for Energy Supply Units

<

20

>

VGB-Standard

Ausgabe/edition 2015 – VGB-S-831-00-2015-05-EN
DIN A4, 107 Seiten, Preis für VGB-Mit­glie­der € 420,–, für Nicht­mit­glie­der € 630,–, + Ver­sand­kos­ten und MwSt.
DIN A4, 107 Pa­ges, Pri­ce for VGB mem­bers € 420.–, for non mem­bers € 630.–, plus VAT, ship­ping and hand­ling.

Lieferung der Technischen
Dokumentation(Technische Anlagendaten,
Dokumente) für Anlagen
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The provision of an energy supply unit its plant sections and their individual components in the context ofprojects and under the scope of individual orders entails the supply of the documentation required for operation and maintenance.
This is necessary to ensure safe and efficient operation of the energy supply unit andequipment.
Although projects very clearly describe the scope of a supply of energy supply unit
and equipment, when it comes to the documentation often substantial differences exist
between the employer’s expectations and the contractor´s actual deliveries.
This is partly due to the documentation structure not being laid down in advance, a lack of definition of the documentation scope of supply, andthe wide variety of terms used when describing documentation.
The purpose of this Guideline is to establish a framework for the– documentation contents (requirements for documents and data), – documentation structure and form,– designation of documents,– assignment of documents to reference designations (KKS, RDS-PP®),– delivery periods, handing over and taking over procedures, and – plant labelling.
With the revised edition of the VGB-Standard VGB-S-831-00 (Former VGB-R 171e) created in 2010 the above mentioned requirements were
met. The experience gained in its application however revealed a need to further detail the stipulations and explicitly integrate the topic ofprovision of technical plant data as an increasingly prioritized part of the documentation.
The classification of the technical plant data follows mainly international standards. Further standardization is being driven in cooperation
with eCl@ss.
The requirements of civil engineering have been considered in agreement with the Central Federation of the German Construction Industry(Hauptverband der Bauindustrie) and the VGB Civil Engineering Working Panel.
The specific demands of the wind industry for their energy supply units have been integrated into the present edition.
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