ALSTOMFlue GasDesulfurizationTechnologies2003AgendazALSTOMEnvironmental Control SystemszFGD Technologies–Wet Flue Gas Desulfurization–Dry Flue Gas Desulfurization–Seawater Flue Gas DesulfurizationzSummaryALSTOM TodayTransportEnergyThe global specialist in energy and transport infrastructure.The global specialist in energy and transport infrastructure.3PowerReorganized into three sectors:zPower Service–No. 1 in service–Largest installed base ofequipmentzPower Turbo Systems–No 1 to No. 3 in steamturbines, generators andpower plant engineeringconstructionzPower Environment–No. 1 in boilers, environmentaland hydro–New regulations driving marketgrowthSales:10.9 billion eurosOrders received:8.4 billion eurosThe Full Service Provider in Power GenerationThe Full Service Provider in Power Generation4In the rear mirrorSvenskaFläktfabrikenNorskViftefabrikk1920DanecoWidmer& ErnstCombustion Engineering19971989ALSTOM PowerALSTOM Power20001999ABBABBAlstomEnergyAlstomEnergyABB AlstomPowerABB AlstomPowerASEABrown Boveri1988ABBABB1000 people1000 peopleworldwide withworldwide witha 600 MEUR businessa 600 MEUR businessProcess TechnologieszParticulate Removal–Electrostatic precipitators (wet and dry) & SO3 conditioning–Fabric FilterszGaseous Emissions, FGD–Limestone (wet), lime (wet/dry)and seawater desulfurizationzPost Combustion DeNOx–Selective Catalytic Reduction (boilers)–SCONOx (GT)–Hugurea to ammonia systemszKnowledge Based IT Solutions–Pegasus neural network applicationszIntegrated Emission / Heat Recovery–ETS for petrochemicalOur Complete SolutionszGreen field, retrofit, upgrade installationszFull range of environmental systems, products,components & serviceszTurnkey project management and Engineeringfrom initial concept to handoverzPost-installation maintenance & assistancezMore than 30 years of global references inPower plants and industrial applicationsWho We AreEurope, MiddleEast & AfricaBusiness RegionOslo, Norway(126)-Helsinki, Finland (54)-Vaxjo, Sweden (146)-Milan (43) and Udine (40), Italy-Moscow, Russia (14)-Butzbach, Germany (41)HeadquartersVelizy,FranceAsia Pacific Business RegionKobe, Japan (72)-Calcutta, India (103)-Sydney, Australia (31)-Beijing/Shanghaii, ChinaNorth America Business RegionKnoxville, TN USA (344)Latin America Business RegionSao Paulo, Brazil (20)GLOBAL ExperienceLOCAL SolutionsENVIRONMENTAL ComplianceFGD ExperiencePersonnelzInternational FGD OfficeszOslo, NorwayzVaxjo, SwedenzMilan, ItalyzSydney, AustraliazKobe, JapanzKnoxville, USAzOver 1500 man-years of FGDknowledge and experience inUSA office alonezMulti-Discipline InternationalEngineering CapabilitieszGlobal Equipment SourcingALSTOM Flue Gas DesulfurizationTechnologiesDry Flue Gas DesulfurizationSpray Dryer AbsorberWet Flue Gas DesulfurizationSeawater Flue GasDesulfurizationDry Flue Gas DesulfurizationNIDWet Flue Gas DesulfurizationSystemsWet FGD ExperiencezSO2Removal EfficienciesGreater than 98%zAvailability Greater than98%zExperience with Low toHigh Sulfur Fuels (4.5% S;>5,000 ppm SO2)zCommercial GradeByproductssuch as Gypsum orByproducts for LandfillzLow Cost/Optimal DesignzNew and Retrofit ProjectsSual Units 1 & 2 Generating StationSual, PhilippinesRecent WFGD ReferencesCustomerPlantMW%SStart-UpCountrySanAntonioCPSBJ.K.Spruce15460.61992USIsefjordverketAsnaes56502.51993DKTaiwanPowerCo.LinKou1&22x3502.01994TWTennessee ValleyAuthorityCumberland 1&22x13004.01994USVirginiaPowerClover1&22x4401.71994/95USGPU-GENCOConemaugh1&22x9362.81995USOhioEdisonCompanyNiles1333.51995USZEPAKKonin7&81101.01997PLSaltRiverProjectNavajo 1,2,33x8030.61997-99USMirantSual1&22x6091.01998PHEnergotransMelnikI6x552.01997CZENDESACompostilla II3301.81997ESKKABKarlshamn3403.51997SEEGATMae Moh4-74x1502.41999THCommunityofRandersRanders2x402.01999DKTransAlta/PacifiCorpCentralia 1 &22x7301.02001-02USEdisonMissionEnergyHomerCity6923.72001USPPC(GreekPowerAuthority)Florina3303.02003GR32,900 MW Total Installed/Under ContractWFGD Process Flow DiagramSTACKWATERSPRAYTOWERABSORBERRECLAIM WATERTANKTOBALLMILLELECTROSTATICPRECIPITATORMAKE-UPWATERTANKLIMESTONEHYDROCLONEAIRBELTFILTERReagent:LimestoneByproduct: GypsumEfficiency: >97%, High SGYPSUMFROM MWTANKBALL MILLLimestone/Forced OxidationSO2(Sulfur dioxide)H2O(Water)CaCO3(Calcium carbonate,limestone)O2(Oxygen)CaSO4•2H2O(Calcium sulfate,gypsum)CO2(Carbon dioxide)SO2+ CaCO3+ 1⁄2O2+ H2O→CaSO4•2H2O + CO2Open Spray AbsorberzCountercurrent flue gas /scrubbing liquorzSize/cost increases with:–Gas flow–Sulfur inlet loading–Removal efficiencyzMaterials of construction:–Flake-lined steel–Rubber-lined steel–Stainless steel–Nickel-based alloys–FRP–Tile LinedzLiquid to Gas Ratio (L/G)–Inlet SO2Concentration–SO2Removal Requirement–Scrubbing Liquor pH–Spray Zone Height–Spray Nozzle Characteristics–Chlorides (HCl gas)–PEP–Absorber Gas Velocity–Similar Plant ExperiencezReaction Tank–Limestone dissolution,gypsum formation–Liquid Residence Time–Solids Residence TimeWFGD Design BasisAbsorber DesignAbsorber Spray ZoneSpray HeaderszCountercurrent slurry sprayzStaggered headerszSingle vessel penetrationzExcellent gas / liquid contactzExcellent turndownzLow pressure losszHigh reliability,low scale potentialPerformance Enhancement PlatesMaterials of ConstructionzFRPzMetallicHigh Efficiency with PEPPerformance EnhancementPlates (PEP)zPrevents wall sneakagezReintroduce wall slurryzImproves efficiency/reduces L/GzPower savings due tolower L/GzFRP or alloy constructionConventionalConventionalPEPPEPSavings: 400-500 kW for 500 MW plantSpray Zone SO2MappingzDifferential Optical AbsorptionSpectroscopy–Alstom proprietary–SO2measurement inside absorber–1 inch space resolution–5 ppm SO2resolutionzComputational Fluid DynamicszTest Facilities–Switzerland (Chemistry)–Sweden (Mass Transfer)–USA (CFD, Mist Eliminators)Absorber Spray NozzlesSpray NozzleszHollow cone, ramp stylezNitride bonded silicon carbidez8 psig at 250-400 gpmz90-120° Spray cone anglez300-600% spray coveragezDroplet size range 200-2000micronsLaser Measurement ofDropletSize DistributionAbsorber Recycle PumpsAbsorber Recycle PumpszEach pump has its owndedicated spray levelzScrubber liquor flow can betailored to systemrequirements to meetturndown needs.zHigh availability with sparepump / levelzHeavy duty, high efficiencypumps (>90%)zNewer, higher capacitypumps reduce FGD costs.Advanced WFGD FeaturesSO2Removal:97%-98%Availability97%-98%GasVelocity:13.1ft/sec(4.0m/sec)No.Spray Elevations:3-4Spray Zone:High efficiency sprayzone;PEP,Increasedspray heightSprayPumps:Increased capacity:72,000+gpmeachSpare Absorber:NoAbsorber/Stack:CombinedMistEliminators:2+2 Plus,Koch,MuntersMaterials:Flakeglass orRubberLined CS,SSorAlloyC276 Roll-CladOxidation:Lance InjectionReheat:NoByproduct:CommercialgypsumLimestone PreparationLimestone grinding•Horizontal/verticalwet ball mills•On-site vs. off-sitepreparationProduct ground to90-95% < 40μ; 30-35% solidsRubber-lined withhardened steel ballsSingle Ball MillzSingle 100% capacity millzPre-ground limestone siloprovided in case ofunplanned mill outagezMost applicable to:–Smaller units (< 500 MW)–Lower sulfur coals (<2% S)zCareful consideration to:–Pre-ground limestone supply–Mill maintenance planningSavings: $3-5 millionLimestone Preparation IslandWallboard Gypsum ProductionTypical specification:z>95% CaSO4.2H2Oz<0.5-1.0% CaSO3.1⁄2H2Oz<100 ppm Clz<10% moisturezpH 6 -8z30-40μ MMDRequires:zHigh purity limestone (95-96%)zHigh efficiency ESPz99+% oxidationzBelt filter or centrifugezCake washing/purge streamPrimary DewateringHydrocycloneGypsum Hydrocyclone:zHeavy, coarse particlesto underflow tosecondary dewateringzLighter, fine particles tooverflow includingflyash, limestonezNo moving partsVacuum Belt FilterSlurry feedCake washProductdischargeWFGD General ArrangementIntegrated Scrubber/StackzAbsorber/chimney integratedinto single structurezAdvantages:–Lower capital cost–Smallerfootprint–Shorter construction durationzKonin Units 7 & 8–2 x 55 MW in Poland–Began operation in 1997–Rubber-lined/concreteconstructionRegional Power Companyof PolandKonin Station Units 7&8 -2x 55MWAdamon,Konin, PolandSavings: Up to $2-5 million; 1-2 monthsRange of ExperiencePlant Size (MW):175 to 2,600Boiler Size (MW):130 to 1,300FuelCoal, lignite, Orimulsion, oilAbsorber Size (MW):130 to 700Sulfur Range (%):0.5 to 4.5SO2Inlet Concentration:5,200 ppm / 15,000 mg/Nm3SO2Removal Efficiencies (%):85 to 99Reagent:Limestone, Lime, FlyashBy-Product: Gypsum,LandfillReheat:Wet Stack, By-Pass, Indirect, RegenerativeChlorides (ppm):1,000 to 120,000FGD Make-Up Water:River, Lake, Plant Waste, SeawaterRecent WFGD ProjectDetailsCentralia Units 1 & 2TransAltaProject ScopeConsortium Alliance:absorbers,reagentprep,dewatering,ductwork,IDfanmodifications,stack,buildings, electrical, DCSpiping, BOPLocationWashington,USACapacity2 x700 MWScheduledStart-UpUnit2– Dec31, 2001Unit1– Dec31, 2002CommercialOperationUnit2– Nov16, 2001Unit1– Dec31, 2002Fuel1.05%sulfurcoalSO2Removal91%No.Absorbers1 perboilerNo. SprayLevels3+1AbsorberSize58 ft.(17.7 m) dia.ByproductWallboard gypsumHighlights30 mo. Schedule;317LMN absorberTransAltaCentralia Units 1 & 2 -2x 700 MWLewis County,WATransAlta Centralia Units 1 & 2Materialsof ConstructionAbsorberSolid 317LMNReaction TankSolid 317LMNInternalSprayHeaders317 LMNExternalSprayPipeFRPPEP317 LMNOutletDuctSolid 317LMNRecycle PumpsRubber linedcasing,metal impellerInletDuctAlloy 276solid, 12 feetMist EliminatorsFRP, MuntersMist EliminatorWashPipe /NozzlesFRPOxidation AirLances317 LMNHomer City Unit 3Edison Mission EnergyALSTOMScopeTurnkey:absorbers,reagentprep,foundations,dewatering,ductwork,stack,buildings, electrical,piping,BOP,wastewatertreatmentLocationPennsylvania,USACapacity1 x650 MWStart-UpSept2001Fuel3.7%sulfurcoalSO2Removal98%No. Absorbers1No. SprayLevels4+1AbsorberSize59ft.(18.0 m)dia.ByproductWallboard gypsumHighlights29 mo.Schedule;C-276roll-cladabsorber;SCRson Units1,2,&3.EdisonMission EnergyHomer City Unit 1 -1x 650 MWHomer City, PAEME Homer City Unit 3Project Features•TurnkeyAlstomProject•Award:April 17, 1999•FGDInService:September21, 2001•Performance Test:October,2001•Single 650 MWAbsorber•WetFGDwith SCR•Construction Management:Alstom•Contractors:ChattanoogaBoiler &Tank,McCalls,DukeFluor Daniel,MPS•29 MonthProjectScheduleEdisonMission EnergyHomer City Unit 1 -1x 650 MWHomer City, PADry Flue GasDesulfurizationSDA and NIDAlstomstarted DryFGDin 1980•More than 20 years ofexperience in Dry FGD•More than 120 systemsinstalled today•Rotary SDA, Nozzle SDA,Fluidized bed and NIDsystems for all kind ofdifferent fuels inoperationDry Flue Gas DesulfurizationSouth Carolina Electric &GasCope Unit 1, 385 MWA History of Dry FGD SystemsCirculating fluidized bedSprayabsorption100%50%0%NIDDryabsorptionwithspraycoolerSpraying reactorFabricfilter /ElectrostaticprecipitatorFabricfilterWaterWaterWaterLime milk-Verybig reactorHÇDÈ-Dustseparator-High energyconsumptionbecause ofrotaryatomizerorspraynozzles-Handling of lime milk-Absorbens:limestone-High coolingtowerHÇDÈ-Dust separator-No lime milk-Absorbens:calcium hydrateSprayingreactorFabricfilter-Small reactor-Dust separator-No lime milk,but Ca(OH)2-Absorbens: calciumhydrateCirculatingfluidizedbed reactorFabric filter/Electrostaticprecipitator-Noseparatereactor-Dustseparator=reactor-No lime milk-Absorbens: quicklimeAlstom’sDryFGDin 2003Formosa Heavy Industries Co.Taiwan, 2 x 150 MW NIDThe NID ProcessNID Process ConceptTCESP or Fabric FilterRecirculationHumidifierWaterReagentEnd ProductzVery high recirculationzNo slurry handlingzDirect usage of CaOz“Dry” productzHigh utilization of reagentSDA and NID –MoistureContent in DustMuch less water is inthe recirculation loop.ÆEnergyand costsavings.% H2O70Thinslurry605040Thickslurry3020Paste10FreeflowingdustWet/DryProcessNID DryProcessAdsorbed equilibriummoisture5NIDNID Design ParameterszFlue Gas SO2Content8Tested up to 3500 ppm8Most applications are forlow and medium sulfurcoal.zFlue Gas Inlet Temperature8Low temp preferred; max approx.. 200 °CzGas flow8Operating range from 20,000 Nm3/h8SingleReactormodule up to Nm3/h8Parallel reactorsforhigherflowsNID –AdvantageszIntegrated FGD and ESP or Fabric Filter saves spacezHigh SO2 removal efficiencyzLower operating cost than comparable systemszLower investment than ESP + Wet FGDzNo separate Dust Removal system necessaryzLess maintenance due to less equipmentzLess maintenance due to no corrosion -No waterspraying and 100 % removal of SO3.NID Standardised componentsReactor layout (NID & others )NID•Same flow velocity in whole reactor.•Same lifting force all the time•Agglomerates are following the flow•No water spraying insidereactor/flue gasOther•Lower velocity in upper part ofreactor, acceleration through venturi•Lower lifting force in upper part•Agglomerates are to a higherextend collected in the reactorand can’t leave it•Water addition inside reactorNID EquipmentMixer/HydratorRecycleCaO



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) 2H2OHydratorMixerDispersion Plate(inside the Reactor)NID Integrated Lime HydratorPrincipleLimesiloCaOMixerRecycleWaterLimeHydratorStage 1HydratorStage 2Mixer/Hydrator installationNID Equipment -Mixer–Mechanically Stirred Fluidised Bed–Low Specific Power Consumption enables a VeryLarge Capacity per unit–Positive wetting of all recycle as opposed to othersystem with wetting inside Reactor.–Enabling factor for CFB + NID; residence time in mixeris long enough to allow activation of ash, in total 15 -25 minutes (20 s x no. of passes)Journey through the NIDReference ListI.NID and ESPII.NID and Fabric FilterIII.NID for Waste to Energy PlantsIV.CFB Boiler and NIDNID Reference PlantsPowerPlantFuelNm3/hYearLaziska, PLCoal2 x 518,00096/97Vaasa, FIDiesel145,0001998Nuremberg, DECoal168,2001999Fifoots Point, UKCoal 3x450,0002000Zhejiang #8, CNCoal330,0002001Mai Liao RF-1, TWPetcoke 2x511,5002002Seward, USCoal2 x 930,0002004Gilbert, USCoal900,0002004Elektrenai #8, LIOrimulsion520,0002004HuaYingShan, CNCoal451.0002003Baotou #2, CNCoal850,0002004NID End Collector OptionsFF and ESPNID + ESPNID-ESP, JuhuaGroup Co.P. R. ChinaZhejiang, JuhuaGroup Co.Process descriptionboiler No 8Zhejiang, JuhuaGroup Co.NID plant data boiler No 8Power productionMain fuelFlue gas flowTemperatureInlet SO2SO2removal efficiencyAbsorbentDust emission, outlet NIDEnd product conveyingEnd productIn operationSteam plus 55 MWeCoal330 000 Nm3/h148 °Cmax. 1 100 ppm85 %Ca(OH)2alternatively CaOmax. 200 mg/Nm3Dense phase pneumatic systemLandfillYear 2001NID ESP Design specials•Low operating temperature -> insulation•High dust load -> purging, rapping•Control and rectifiersEPIC II controlT/R of correct size•Slightly higher ESP power consumption than inoperation with low resistive coal•Sizing of ESP: For coal case and NID caseNID + Fabric FilterVaasaDiesel Power Plantprocess description



VaasaDiesel Power PlantEWAG NürnbergReplacement of SDAwith NIDEWAG NürnbergNID basic plant data114 MWtCoal157 000 Nm3/h140 °C1800 mg/Nm3max. 180 mg/Nm3CaOmax. 10 mg/Nm3Dense phase pneumatic systemLandfillYear 1999Power productionMain fuelFlue gas flowTemperatureInlet SO2Outlet SO2AbsorbentDust emission, outlet NIDEnd product conveyingEnd productIn operationNID –Laziska Basic Plant Data2 x 120 MWCoal, max 1.4% S2 x 518.000 Nm3/h165°C1,500 –4,000 mg/Nm380% (guaranteed)95% (measured)CaO22,000 mg/Nm3 (no precollector50 mg/Nm3 (guaranteed)15 mg/Nm3 (measured)Stabilisate/fire prevention in coal minesDense phase pneumatic system1,200 m (tested)Power productionMain fuelFlue gas flowTemperature, maxSO2 inletSO2 removal efficiencySO2 removal efficiencyAbsorbentDust load, inlet NIDDust emission, outlet NIDDust emission, outlet NIDEnd product utilisationEnd product conveyingConveying distanceFifootsPoint -ExteriorAES FifootsPointNID LayoutNID –Fifoots Point Plant Data3 x 120 MWCoal, 1.2% S3 x 450.000 Nm3/h133°C800 ppm80% (guaranteed)CaO25 mg/Nm3 (guaranteed)Dense phase pneumatic systemPower productionMain fuelFlue gas flowTemperatureSO2 inletSO2 removal efficiencyAbsorbentDust emission, outlet NIDEnd product conveyingMai LiaoSite sept2002Mai Laio-Control ScreenSeward, USANID for CFB 2*250 MWSeward, USANID -Technical dataTypeCFB + NIDSize 2*250MWelGas flow2*906 000Nm3/hIn operationDec 2003Emissions guaranteesDust10mg/Nm3SO2 emission318ppmSO2 removal overall95%(Boiler + NID)ALSTOM Technology moves onNID Pilot Plant in Alstom’sLaboratory:R+D test runs lead to new developmentsALSTOM Seawater FGD30 years operation and developmentSuccessful applicationsSeawater availableLow-medium sulfur contentCoal and Oil-fired Power StationsMetal smeltersOil industrySeawater FGD Process DiagramSTACKABSORBERELECTROSTATICPRECIPITATORAIRSEAWATERTREATMENT PLANTSEAWATERRETURNSEAWATERFROMBOILERCONDENSERSReagent:NoneByproduct: NoneEfficiency: >95%, Low/Med. SProcess flowAbsorber designWater treatment plantSeawater FGDzUtilizes naturalalkalinity of seawaterzHigh efficiency viapacked towerzNo reagent, nobyproductzEffluent treated viaoxidation prior todischargeRecent SWFGD ReferencesCustomerFuelMWStart-UpUNELCOTenerife, SPOil 2x1601995Shenzhen West PowerUnit 4, CNCoal 3001998MitsuiPaiton, IDCoal 2x6701998/1999TNBJ Manjung, MYCoal3 x7002002/2003Shenzhen West PowerUnit 5 + 6,CNCoal 2x3002004Vasilikos II EA CyprusOil1302005Over 8,000 MW Operating or Under ContractShenzenWest SWFGDSummaryFGD AlternativesWFGDDFGD-SDADFGD - NIDSWFGDInstalledCapacity33,000MW12,000MW3,000MW8,000MWFirst Installation1968198019961968Reagent LimestoneLimeLime(Limestone withCFB)SeawaterByproduct SalablegypsumorlandfillLandfillLandfillorUseinCement/RoadConstrTreated SeawaterSulfur<6% <2.5% <6%<2%RemovalEfficiency>98% 90-95%90-95%(98% w/CFB)>95%FootprintSmall inpower islandarea; largeoverallLarge inpower islandarea; smalloverallSmall inpower islandarea andoverallSmall inpower islandarea; moderateoverallPros•Lowcost reagent•Marketablebyproduct•Large referencelist•Fuel flexibility•Easeof retrofit•Lowcapitalcost•Lowpowerconsumption•Drybyproduct•Operationalsimplicity,mediummaintenance costs•Lowcapitalcost•Lowpowerconsumption•Drybyproduct•Operationalsimplicity,lowmaintenancecosts•Noreagent•Nobyproduct•FuelflexibilityCons•High capitalcost•High powerconsumption•High cost reagent•Byproduct uselimited•High costreagent•Byproduct uselimited•Moderatecapitalcost•Effluent discharge•Limited applicabilityWhy ALSTOM?zA diverse portfolio of proven FGDtechnologies–Wet Flue Gas Desulfurization–SDADry Flue Gas Desulfurization–NID Dry Flue Gas Desulfurization–SeawaterFGDzNumerous and recent references in alltechnologies with over 55,000 MW ofFGD installationszExperience over a wide range of siteand process conditionszFGD personnel and offices locatedaround the world with both FGD andlarge project capabilityKarlshamn Full ScaleExperience9Start-up:November 19969340 MW Flowpac WFGD9Patent Owner: AlstomNew DevelopmentsNo Recycle PumpsEnergy fromoxidation blowerand fan used inplace of recyclepumps.Flowpac Advantages•97-98% SO2collecting efficiencywith high sulfur content.Excellent reagent utilization.•70% SO3removal and highparticle collecting efficiency•No scaling or corrosionproblems•Lower maintenanceandsupervision costs due to lowoverall height and absence ofslurry pumps, absorber headers,and nozzlesKarlshamn -Sweden