Wet Flue Gas Desulphurization System

Transcription

1 Introduction of Babcock-Hitachi K.K. Wet Flue Gas Desulphurization System March 12,, 2012 Babcock-Hitachi K.K. Promising to contribute to global welfare with technologies of energy and environment systems Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 1

3 Babcock-Hitachi in HITACH Group President Mr. Hiroaki Nakanishi Corporate Corporate Staff Staff Intellectual Intellectual Property Property Division Division R&D R&D Division Division Power Systems Company Industrial Industrial & Social Social Infrastructure Infrastructure Systems Systems Company Company Information Information & Control Control Systems Systems Company Company Urban Urban Planning Planning & Development Development Systems Systems Company Company Mr. Tetsuro Wakino Babcock Hitachi (100% (100% Owned) Owned) Thermal Thermal Power Power Systems Systems Division Division Boiler Boiler and and Air Air Quality Quality Control Control Systems Systems Division Division Hydroelectric Hydroelectric Power Power Systems Systems Division Division Nuclear Nuclear Systems Systems Division Division Power Power & Industrial Industrial Systems Systems Division Division Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 3

4 Power Systems Company of HITACHI Coal Fired PP Thermal Power Business CO2 Capture Solution AQCS 60% Gas Turbine (ABWR, ESBWR) 20% FY2010 SALES 813.2B 20% GTCC, Preventive Maintenance, etc. Wind Power Sys. Solar Power Sys. Power Device <Major Equipment> RPV Nuclear Equipment Preventive Maintenance, Fuel Cycle, etc. Central Control Panel Nuclear Power Business Blue : Products of BHK Hydro Power Sys. Others Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 4 PBT Smart Grid, Transmission & Distribution System PET Service, etc.

5 Outline of Babcock-Hitachi K.K. Babcock-Hitachi K.K. Segment of Power & Environmental in Hitachi group Stock holder: Hitachi Ltd. (100%) - Established Employees 3,200 (Worldwide) - Head Office Tokyo, Japan -Works Kure 1st & 2nd, Noumi, Akitsu Philippine (BHPI), China (BHDB) - Laboratories Kure, Akitsu - Affiliated Companies Domestic : 2 / Overseas :3 - Quality Certificates ISO 9001, ISO 14001, ASME S, U and U2 Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 5

6 Company History Hitachi, Ltd. Hitachi Works Boiler Manufacturing Department established Babcock-Hitachi established Hitachi Works Kure Branch Works established Kure Branch Works became independent from Hitachi Works Totally independent from Hitachi Ltd. Merged (Capital 1,235million) (Capital 1,852.5 million) (Capital 2,637.5 million) (Capital 3,000 million) Share Holding Ratio amounted to 100% of Hitachi, Ltd. (Capital 5,000 million) Babcock Borsig Power Systems (BBPS ) acquired Hitachi Power Systems America (HPSA) established Hitachi Power Europe (HPE) established B&W UK Zenma Works Ltd. established Corporate name changed to Toyo Babcock Ltd. [Expansion on Production Locations] [Expansion on Production Locations] Akitsu Akitsu Works Works Noumi Noumi Works Works Philippines Philippines (BHPI) (BHPI) China China (BHDB) (BHDB) Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 6

7 Main Products Power Boilers Incinerators HRSG Integrated & Dedicated Product Line-up for Power and Industrial Plant Industrial Plants Industrial Boiler FGD SCR Nuclear Power Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 7

8 Office & Works in Japan Head office Kure First Works Kure, Hiroshima, Japan Design and manufacturing of boilers Kure Second Works Kure, Hiroshima, Japan Manufacturing of nuclear power related products Location: Akihabara UDX Building, Tokyo Japan Noumi Works Edajima, Hiroshima, Japan Manufacturing of heat recovery steam generators and other products Akitsu Works Higashihiroshima, Hiroshima, Japan Manufacturing of catalysts Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 8

9 HITACHI Global Network for Boiler and AQCS As a core company of the HITACHI/Power&Industrial group, we provide boiler and AQCS services globally Global Network Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 9

10 Works Worldwide Hitachi Power Europe GmbH (HPE) Duisburg, Germany Engineering, procurement, manufacturing and sales of boilers, AQCS and related equipment. Hitachi Power Systems America, Ltd. (HPSA) Basking Ridge, NJ, USA Engineering, procurement and sales of boilers and Air Quality Control System (AQCS) Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 10

11 FGD retrofits HITACHI formation Customer EPC contract Joint & Several Consortium Babcock-Hitachi K.K. Hitachi Power Europe Local partner Sub-Contractors Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 11

12 FGD retrofits complete solution on cooperation with Knauf Gips Customer Off-take contract EPC contract Knauf Gips KG Cooperation Babcock Hitachi K.K. Hitachi Power Europe GmbH Sub-Contractors Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 12

13 Knauf Reference Example Gypsum wall board plant near the power station power station FGD Gypsum store Gypsum Wall Board plant Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 13

15 Japanese regulation of flue gas treatment 100 SO 2 :100ppm (285mg/Nm³) Dust Conc. (mg/nm³) SO2 Conc. (ppm) NOx:70ppm (144mg/Nm³) Dust:20mg/Nm Dust: 20mg/m 3 3 N ~ ~ SO 2 :50ppm (142mg/Nm³) NOx:50ppm (103mg/Nm³) Dust:10mg/Nm 10mg/m 3 N NOx:35ppm (71mg/Nm³) SO 2 :25 ppm (71mg/Nm³) Dust:5 mg/nm 3 (Year) Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 15

16 Air Quality Control System (AQCS) Boiler DeNOx(SCR) AQCS Air Quality Control Systems FGD Stacks ESP Boilers A/H DeNOx (SCR) ESP FGD (Layout for 1000MW coal fired plant in Japan) Stack FGD : Flue Gas Desulfurization Hitachi is is one of of few AQCS Supplier for total system Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 16

17 Measures for SO 2 Reduction Activated carbon method Dry Process Fly ash method Activated coke method Semi-Dry Process Wet Process Spray Dryer Absorber (SDA) Circulating Dry Scrubber (CDS) Limestone Injection into Furnace and Flue Gas Humidification Limestone-Gypsum method Magnesium Hydroxide -Gypsum method Sea water method Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 17

18 FGD Process: Wet Limestone-Gypsum Process Technical Response to Emission regulations Forced oxidation limestone gypsum process as almost standard technology (after technological and economical comparison) Reasons for the wide application of Wet Limestone-Gypsum Process 1) Limestone* is Cheapest Absorbent Abundant in nature Easy Handling 2) Gypsum is Useful for Cement Additives Useful for Wallboard Materials Easy Storing Easy Handling 3) The System is Simple Easy to Operate High Reliability High efficiency Performance optimisation and cost reduction results in highly standardised absorber * also quick lime technology available (Walsum Power Plant - Branntkalk) Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 18

20 Development of Hitachi WFGD System Improvement of Reliability Meeting Middle Load Ope. Initial Stage Reduction of Utility Simplification of the System PERFORATED TRAY TOWER SPRAY TOWER Targeting Low Utility and Cost ADVANCED SPRAY TOWER LIMESTONE GYPSUM FGD SYSTEM PERFORATED TRAY TOWER R&D / PILOT COMMERCIAL PLANT ( Total 15, - COAL 3, OIL 12 ) SPRAY TOWER ADVANCED SPRAY TOWER COMMERCIAL PLANT ( Total 9, - COAL 4, OIL 3, COM 1, PET COKE 1 ) COMMERCIAL PLANT ( Total 52, - COAL 41, Lignite 3 ORIMULSION 2, OIL 2, PET COKE 2, R.O. 2 ) TAMASHIMA #3 500MW MATSUSHIMA #2 500MW MATSUURA #1 1,000MW TACHIBANAWAN #2 1,050MW TRAY TOWER SPRAY TOWER ADVANCED SPRAY TOWER Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 20

21 Wide Application of BHK WFGD System COAL / LIGNITE OIL BHK FGD SYSTEM RESIDUAL OIL ORIMULSION P. C. FUEL BHK'S EXPERIENCE 1. OIL 2. COAL 3. COM 4. ORIMULSION 5. RESIDUE OIL 6. PET.COKE INLET SO2 CONCENTRATION (ppm) Applied many kinds of fuel Experience of high sulfur fuel BHK FGD can be applied to any kinds of fuel and various sulfur containing fuel Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 21

22 Principle and System Flow of BHK Wet FGD System LIMESTONE MILL LIMESTONE STACK BOILER ESP FAN LIMESTONE PREPARATION SYSTEM GAS-GAS HEATER AIR WASTE WATER GYPSUM DEWATERING ABSORBER ABSORPTION SYSTEM GYPSUM GYPSUM RECOVERY SYSTEM CHEMICAL PRINCIPLE: SO 2 Absorption and Oxidation SO 2 +2H 2 O+CaCO 3 (LIMESTONE) + 1/2O 2 CaSO 4 2H 2 O(GYPSUM)+CO 2 Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 22

23 Absorption system LIMESTONE MILL LIMESTONE STACK BOILER ESP FAN LIMESTONE PREPARATION SYSTEM GAS-GAS HEATER AIR WASTE WATER GYPSUM DEWATERING ABSORBER ABSORPTION SYSTEM GYPSUM GYPSUM RECOVERY SYSTEM CHEMICAL PRINCIPLE: SO 2 Absorption and Oxidation SO 2 +2H 2 O+CaCO 3 (LIMESTONE) + 1/2O 2 CaSO 4 2H 2 O(GYPSUM)+CO 2 Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 23

24 Principle of BHK Advanced WFGD System (Chemical Reaction in Absorber) SPRAY NOZZLE SLURRY Pso 2 DROPLET Xso 2 GAS FILM LIQUID FILM GAS ABSORPTION AREA DROPLET FLUE GAS:SO 2 SO 2 +2H 2 O+CaCO 3 +1/2O 2 CaSO 4 2H 2 O+CO 2 CLEAN GAS TANK AREA ABSORPTION AREA AIR ; FLUE GAS AIR TANK AREA (LIMESTONE) (GYPSUM) CHEMICAL REACTION SO 2 Absorption and Oxidation SO 2 +2H 2 O+CaCO 3 (LIMESTONE) + 1/2O 2 CaSO 4 2H 2 O(GYPSUM)+CO 2 Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 24

26 Absorber Design Absorber Outlet (horizontal or vertical) Mist Eliminator (2 3 stages, depending from allowable drop content) Absorption Area SO 2 & Dust Removal Spray Levels (number of levels depending on sulphur in fuel, if desired with space for retrofit of spare level) Absorber Inlet Spray Nozzles (up and/or down spray nozzles) Absorber Sump Oxidation Dissolution of Limestone Crystal growth Absorber sump (with agitator for mixing and oxidation air injection) Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 26

27 Absorber Material Rubber Lining Application European Solution: Rubber Lined Absorber Spec. A Rubber lined 2 x 6 mm Spec. B Rubber lined 1 x 6 mm Spec. C Alloy plated Lifetime of more than hours, Maintenance and repair of coating by rubber lining specialist company only! Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 27

28 Absorber Material Flake Lining Application Inspection After 3 Years Operation Wear Resistant FRL or Metal lined Heat Resistant FRL or Metal lined Heat Resistant FRL Spark test: Inspection of lining Acid Resistant FRL Top coat 2 nd layer 1 st layer Primer Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 28

29 Limestone Slurry preparation system LIMESTONE MILL LIMESTONE STACK BOILER ESP FAN LIMESTONE SLURRY PREPARATION SYSTEM GAS-GAS HEATER AIR WASTE WATER GYPSUM DEWATERING ABSORBER ABSORPTION SYSTEM GYPSUM GYPSUM RECOVERY SYSTEM CHEMICAL PRINCIPLE: SO 2 Absorption and Oxidation SO 2 +2H 2 O+CaCO 3 (LIMESTONE) + 1/2O 2 CaSO 4 2H 2 O(GYPSUM)+CO 2 Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 29

30 Flow Diagram of Limestone Slurry Preparation System Limestone Silo Main Process Water W Grinding / Dilution Water Supply H/C Classifier Limestone Feeder M W W W W W Distribution System Ball Mill W M High Low Mill Tank Slurry Pump M Limestone Slurry Tank M Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 30

31 Limestone Preparation - Wet Ball Mill - Quarry Ground Limestone or On-Site Mill - Horizontal Ball Mill or Tower Mill - 95% Mesh (44 µm) - 30% Solids Horizontal Ball Mill Limestone Activity Test H2SO4 consumption (= Limestone Reactivity) Time Standard Photo Horizontal Ball Mill <Before Project Start > Evaluation of Limestone activity Reliable Design Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 31

32 Gypsum Recovery System LIMESTONE MILL LIMESTONE STACK BOILER ESP FAN LIMESTONE PREPARATION SYSTEM GAS-GAS HEATER AIR WASTE WATER GYPSUM DEWATERING ABSORBER ABSORPTION SYSTEM GYPSUM GYPSUM RECOVERY SYSTEM CHEMICAL PRINCIPLE: SO 2 Absorption and Oxidation SO 2 +2H 2 O+CaCO 3 (LIMESTONE) + 1/2O 2 CaSO 4 2H 2 O(GYPSUM)+CO 2 Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 32

33 Gypsum Recovery System - Belt Filter Application Absorber Slurry Overflow Hydro-Cyclone Horizontal Belt Filter By product Gypsum Water for recycling To Absorber Filtrate Receiver Vacuum Pump Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 33

34 Gypsum Recovery System - Belt Filter Application Vacuum Belt Filter Hydrocyclone Slurry feed Direction Vacuum Byproduct Gypsum Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 34

35 Typical Requirement of Gypsum Usage BY-PRODUCT GYPSUM QUALITY ITEM ACTUAL VALUE GENERAL REQUIREMENT IN JAPAN FOR CEMENT FOR WALL BOARD CaSO 4 2H 2 O 98.8 % > 90 % > 95 % CaSO 3 1/2H 2 O < 0.05 % < % CaCO % Na % % ph 6.8 5~8 PHOTO OF BYPRODUCT GYPSUM CRYSTAL Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 35

36 Requirement of Gypsum Quality in Europe BY-PRODUCT GYPSUM QUALITY ITEM H 2 O CaSO 4 2H 2 O MgO Na 2 O Cl CaSO 3 1/2H 2 O ph Color Odour Toxicity EURO GYPSUM Criteria < 10% > 95% < 0.10 < 0.06 < 0.01 < 0.50 % 5-9 White Neutral Non-toxic VGB-M 701e: EURO GYPSUM: Quality Criteria and analysis methods Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 36

37 FGD Design Consideration for Lignite Coal Large Flue Gas Volume High SO 2 Content High Removal Efficiency High Fly Ash Loading High Inlet Gas Temperature High Inlet Moisture High Absorber Slurry Temperature *1 Gas Flow Rate shall be confirmed. Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 37

38 FRP Wet Stack BHK Unique FGD Technology: Wet Stack Solution Wet stack on top of Absorber Stand alone Wet stack Wet Stack Absorber Absorber Features of Wet Stack on top of Absorber (1) Small-footprint (2) Isolated from Absorber Supported by Steel structure and no load to absorber shell Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 38

39 FGD Waste Water Treatment Flowchart (Example in Europe) SS, Heavy Metals Removal COAGULANT Ca(OH)2 TMT-15 FeCl3 Polymer HCl Cooling water Raw FGD Waste Water Neutralization Tank 1 Neutralization Tank 2 Flocculation Tank Lamella Clarifier Treated Waste Water Tank Waste Product Filter Press Sludge Storage Tank Discharge to River Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 39

42 Reference Plant Industry Recognition Ameren Services (USA) / Coffeen Power Plant / No. 1, 2 POWER s 2011 Plant of the Year - Power Magazine (Oct 2011) Project of the Year Award - Power Gen International 2011 in Las Vegas, USA Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 42

44 R&D Facilities Desulfurization Test Facility Boiler-AQCS Pilot Test Facility FF WESP Absorber A Absorber B 4 Absorbers and 1 Reaction Tank Test Facilities e.g. Absorber A Absorber B -Gas flow: 22,000m 3 N/h -Gas flow: 250m 3 N/h -SO 2 conc.: 500 ppm -SO2 conc.: 20,000ppm -Abs. dia.: 680mm -Abs. dia.: 160mm DESP WFGD Flue gas treatment facility Coal Burner SCR SCR Combustion facility Coal Feed Rate 100~150 kg/h Gas Flow Rate 1,000~1500 m 3 N/h Abs. dia: 480 mm G/C GGH DESP FF IDF WFGD WESP GGH CEM Pump BUF Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 44

45 Computational Flow Model < Model Consideration > - Spray Droplets - Kinetic Momentum (Droplet/Gas) Track of Spray Droplet Gas Distribution Flow Model Results Confirmation of Optimized Absorber internal arrangements by Flow Model to prevent the gas short-pass. Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 45

47 Special Features of BHK FGD System Total Engineering Capability with Boiler Plant Engineering corresponding to various kinds of fuel Best-Mix of Japanese & European State of the Art Technologies Excellent Advanced Spray Tower Absorber Design featuring; a) Higher SO 2 Removal Efficiency & Dust Removal Efficiency b) Lower Gas Pressure Drop Less Boost-Up Fan Capacity c) Excellent Liquid/Gas Contact Less Recirc. Pump Capacity d) Higher Quality of By-Product Gypsum Re-Use for Cement Additive and/or Wall Board Material Full Support by R&D Facility Proven FGD Technology and High Reliability Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 47

49 SCR Process SCR ; SELECTIVE CATALYTIC REDUCTION REACTION FORMULA 4NO + 4NH 3 + O 2 4N 2 + 6H 2 O NO + NO 2 + 2NH 3 2N 2 + 3H 2 O 6NO 2 + 8NH 3 7N H 2 O NH3 CATALYST NOx NOx NOx NH 3 NH 3 NH 3 NOx NOx N 2 N 2 H 2 O H 2 O H 2 O CLEAN GAS Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 49

50 Scheme of SCR System NH3 injection SCR Reactor ECO EP DeSOx BOILER Catalyst FDF STACK NOx ANALYZER BOILER LOAD SIGNAL NH 3 STORAGE TANK EVAPORATOR FIC MIXER ACCUMULATOR NH3 Storage & Supply Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

53 SCR Reactor NH 3 INJECTION GRID INLET DUCT MAIN MONORAIL CASING HOIST CATALYST BLOCK OUTLET DUCT SUPPORTING STRUCTURE Babcock-Hitachi K.K. All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K. 53