High SO 2 Removal Performance using Limestone FGD at Tusimice Power Plant

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1 98,3% Desulphurisation Efficiency High SO 2 Removal Performance using Limestone FGD at Tusimice Power Plant Speaker: Klaus Bärnthaler, Franz Hafner, Jan Stancl CLEAN ENERGY SOLUTIONS Date of presentation

2 PROJECT DESCRIPTION CLEAN AIR POLLUTION ENERGY CONTROL SOLUTIONS

3 CEZ Program of Complex Renewal Essentials Horrifying status of environment in Czech Republic in the early nineties huge investment program by CEZ (FGDs, CFBs and upgrade of control system) brought immediate improvement actual target is to meet future power consumption in Czech Republic Some of coal fired power plants at the end of life time expectancy Fulfill stringent emission limits Exploit and use coal reserves Decision of CEZ to renew power plants Tusimice and Prunerov and build a new 660 MW supercritical boiler at Ledvice, at the same time to shut down old and ineffective power plants Execution of the projects by Skoda Praha Invest (SPI) as the EPC contractor AE&E is the turnkey supplier for the FGD plants Page 3

4 Power Plants within the Program of Complex Renewal Current Status Tusimice II PP Prague Current Installed Capacity 4 x 200 MW COD Czech Republic Desulphurization 1997 Prunerov II PP Ledvice PP Current Installed Capacity 5 x 210 MW Current Installed Capacity 2 x 110 MW 1 x 110 MW (CFB) COD COD Desulphurization 1996 Desulphurization 1996 NA Page 4

5 Power Plants within the Program of Complex Renewal Future / Designed Status Tusimice II PP Prague Future Installed Capacity 4 x 200 MW COD 2010 / 2011 Czech Republic Prunerov II PP Ledvice PP Future Installed Capacity 3 x 250 MW Future Installed Capacity 1 x 110 MW (CFB) 1 x 660 MW COD 2014 COD 2013 Page 5

6 TUSIMICE II Scope of Renewal Renewal of 4 x 200 MW Units, lignite In total 16 system packages: Coal handling Boiler house Machine room Water treatment Life time expectancy 25 years Existing FGD replaced by NEW FGD Power feeding Electrical + I&C BOP Total efficiency increase 33 % 38 % Page 6

7 TUSIMICE II Power Plant Basic Data Gross output Fuel Current 4 x 200 MWe brown coal (high S contents; S T D ~3%) Boiler efficiency 86-87,6% NO x emissions mg/nm 3 SO 2 emissions mg/nm 3 Fly ash emissions mg/nm 3 Overall efficiency % Future 4 x 200 MWe brown coal (high S contents; S T D ~3%) > 90% < 200 mg/ Nm 3 < 200 mg/ Nm 3 < 20 mg/ Nm 3 38,67 % Home consumption 9% 8,6 % Page 7

8 TUSIMICE II FGD Main Principles Wet limestone scrubbing method (high sulfur contents in coal) By-product of desulphurization mixed with fly ash + slag disposed as stabilizate (mines) Clean flue gas inducted into the cooling towers One absorber per two boilers Page 8

9 FGD Tušimice - Scope of supply Demolishing of existing Desulphurisation units Chiyoda Turnkey installation of new Wet Limestone Desulphurisation unit for the 4*200 MW (Tušimice) boiler units excluding electrical and control system Raw gas ducts 2 Absorbers for 4 boilers, made of CS / RL incl. internals (agitators, spraying system, mist eliminator) Recirculation pumps, Oxidation air blowers Clean gas duct (into cooling tower; made of FRP) Process water tank and emergency slurry tank Civil work: Foundation, Pump building, Electrical Building New gypsum dewatering system (Eng. by AE, installation by others) Erection and Commissioning Page 9

10 TUSIMICE II FGD Basic Data Volume of wet flue gasses exceeds 1.7 mio Nm 3 /h per absorber (6% O 2 ) Reduction of SO 2 emissions from values reaching 11,326 mg/nm 3 upstream FGD to < 200 mg/nm 3 downstream FGD (dry, 6% O 2 ) Emission limits [mg/nm 3 ] NOx SO 2 fly ash Current Future Page 10

11 TUSIMICE II Key Milestones Contract between SPI & AEE concluded in 2006 Erection activities at site started in 7/2007 Units (Phase I) commissioned; PAC for FGD Units shut down in 10/2009, start of Phase II FGD ready for flue gas take over Scheduled PAC of Phase II in 12/2011 Page 11

12 TUSIMICE II Page 12

13 TUSIMICE II Page 13

14 LEDVICE Basic Information 1 x flue gas cooler, 1 x absorber New supercritical Unit 1 x 660 MW Clean flue gas inducted into the cooling tower Reduction of SO 2 emissions from values reaching 5,500 mg/nm 3 upstream FGD to <150 mg/nm 3 downstream FGD (dry, 6% O 2 ) By-product of desulphurization secondary used (civil industry) Pre-arrangement a e for the future u installation a of the 1 st CCS in CR Total efficiency 42,5% Emission limits [mg/nm 3 ] NOx SO 2 fly ash New Unit Page 14

15 LEDVICE Basic Information Contract between SPI & AEE concluded in 8/2008 Detail design handed over Civil work in progress, mechanical erection well ahead of schedule Scheduled commissioning 6/2012 Scheduled TOC 12/2012 Page 15

16 LEDVICE Page 16

17 PRUNEROV II Basic Information One absorber per one boiler 3 x 250 MW Units Clean flue gas inducted into the cooling towers Reduction of SO 2 emissions from values reaching 11,349 mg/nm 3 upstream FGD to <200 mg/nm 3 downstream FGD (dry, 6% O 2 ) By-product of desulphurization secondary used (civil industry) Emission limits [mg/nm 3 ] NOx SO 2 fly ash Current Future Page 17

18 FGD Prunéřov - Scope of supply Demolishing of existing Desulphurisation units MHI Turnkey installation of new Wet Limestone Desulphurisation unit for 3*250 MW (Prunéřov) boiler units excl. electrical and control system Raw gas ducts 3 Absorbers for EPR II made of CS / rubberlined, incl. internals (spraying system, mist eliminator, agitators, strainers) Recirculation pumps, Oxidation air blowers Clean gas duct (into cooling tower; made of FRP) Process water tank and emergency slurry tank Civil work: Foundation, Pump building, Electrical Building Erection and Commissioning Dewatering system (hydocyclones, vacuum belt filter) Limestone supply system (connected to existing milling system) Page 18

19 PRUNEROV II Basic Information Contract between SPI & AEE concluded in 12/2008 Preparation of the FGD detail design in progress Postponement of contract due to delay in the authority permit Scheduled commissioning and PAC in 2015 Page 19

20 ETU, ELE, EPR Comparison of Key Parameters Tusimice Prunerov Ledvice Wet flue gas [Nm 3 /h] 1,690,000 1,012,000 2,003,041 SO 2 in raw gas [mg/ Nm 3 ] dry 11,650 11,800 5,850 SO 2 removal efficiency > 98,3 > 98,2 > 97,2 Diameter absorber [m] No. of spray banks (spare) Nozzles per spray bank Flow per spray banks [m 3 /h] 11,000 9,800 11,500 Flow per nozzle [m 3 /h] 1,637 1,384 1,230 Mist eliminator coarse / fine coarse / fine coarse / fine Page 20

21 ETU, ELE, EPR Comparison of Key Parameters Tusimice Prunerov Ledvice Sump volume [m 3 ] 3,900 2,500 4,600 Flow oxidation air [m 3 / h] 22,000 11,000 15,600 El. consumption [kwh/h] 4,930 3,650 7,500 Water consumption [m 3 / h] Gypsum moisture [%] - 12 < 8 CaCO 3 in gypsum < 2 < 2 < 1,5 Availability [%] 99 98,8 99 Page 21

22 CFD optimized scrubber design CLEAN AIR POLLUTION ENERGY CONTROL SOLUTIONS

23 CFD Modeling Tool solver settings and general parameters (FLUENT) Pressure based solver, steady-state t t two phases, two-way-coupling, Eulerian-Lagrangian model, discrete random walk turbulence model (discrete phase) k-ε turbulence model (continuous phase) spray generation (Matlab) basis: measurements of the nozzle manufacturer (droplet size distributions) injection informations are tabulated in a list (e.g. position, mass flow, diameter, temperature) description of one nozzle by at least 17 different droplets CFD model of hollow cone nozzle User-Defined-Functions (UDFs) droplet-wall ll interaction ti evaporation and condensation SO 2 chemisorption Page 23

24 CFD Model FGD Tušimice Design Data diameter 14.5 m volume flow m³/h ntp SO 2 at inlet mg/m 3 ntp,dry Spray Bank Design: 5 spray banks double header concept 112 nozzles / spray bank slurry/spray bank m³/h Page 24

25 CFD Model FGD Tušimice - Results Upwards velocity (m/s) at 1 st and 5 th spray bank Page 25

26 CFD Model FGD Tušimice - Results SO 2 mass fraction [-] Page 26

27 CFD Model FGD Prunéřov Design Data volume flow m³/h ntp SO 2 at inlet mg/m 3 std,dry Spray Bank Design - First approach diameter 11 m 4 spray banks 98 nozzles / spray bank First approach slurry/spray banks 4 x m³/h Spray Bank Design - Final geometry diameter 11.5 m AE&E splash rings Increased height of absorption zone 118 nozzles / spray bank slurry/spray banks 4 x m³/h Final geometry Page 27

28 CFD Model FGD Prunéřov-Results Final geometry First approach Upward velocity (m/s) at 1 st and 4 th spray bank Page 28

29 CFD Model FGD Prunéřov-Results Final geometry First approach mass fraction of SO 2 in different cross sections Page 29

30 FGD Tušimice Operational Results ,0 650 ph value 600 6,0 Recycle pumps in operation ph Presurre before FGD [kpa] RP Pressure RP 5 5,0 4,0 3,0 Flue Gas after FGD [Nm3/s, f.] SO2 outlet [mg/nm 3 dry, 6%O2] 20 2,0 150 SO 2 - outlet 100 1, ,0 16:01-16:30 15:01-15:30 14:01-14:30 13:01-13:30 12:01-12:30 11:01-11:30 10:01-10:30 9:01-9:30 8:01-8:30 18:01-18:30 17:01-17:30 21:01-21:30 20:01-20:30 19:01-19:30 06:01-06:30 05:01-05:30 04:01-04:30 03:01-03:30 02:01-02:30 01:01-01:30 00:01-00:30 23:01-23:30 22:01-22:30 07:01-07:30 Time [8:00-7:59] GAS FLOW SO2- OUT DP RECP ph Page 30

31 FGD Tušimice Comparison Design andoperation 99, ,6 99,4 5RPinoperation spray bank oval Efficie ency [%] Rem 99,2 99,0 98,8 98,6 98,4 98,2 98,0 97,8 97,6 Flue Gas Data 4 RP in operation spray bank Design point 5 RP in operation 4RPi in operation spray bank RP in operation spray bank Design point 4 RP in operation Pumps [KW W] nsumption Power Co 97,4 97,2 Volume Flow: 1.69 Mio. m³/h (wet stc) SO 2 -Conc. Inlet: mg/nm³ dry act. O 2 Fuel: Lignite Boiler Size: 2 x 200 MW SO2-Removal Efficiency [%] Energy Consumption [KW] 97,0 0 30,0 50,0 70,0 90,0 110,0 130,0 150,0 170,0 190,0 SO 2 -Cleangas Concentration [mg/nm³] dry, 6% O Page 31

32 Conclusions CLEAN AIR POLLUTION ENERGY CONTROL SOLUTIONS

33 Conclusions ČEZ in cooperation with SKODA PRAHA invest and AE&E adopts latest technologies to improve air pollution control in Czech Republic For high and low sulfur applications different strategies were developed to reach seperation efficieny > 98% in the FGD Systems; For high sulfur applications the number of spray banks could be reduced due to higher suspension flows in the spray bank and in the single nozzles; Flue gas velocity in the scrubber has to be limited to values < 4 m/s to minimize bypass effects near the scrubber walls and the main headers; A proper spray bank design (single main header vs. double main header) is very important for an optimized contact between flue gas and droplets in the absorption zone; Using a strong CFD modelling tool is mandatory to optimize the nozzle position in the spray bank; Including the SO 2 mass transfer in the simulation is the only way to get fully information from the simulation results; Page 33

34 Thank you for your attention

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