Post-combustion stage of Analytical CCT Review

Transcription

1 Capacity Building for Air Quality Management and Application of Clean Coal Technologies in in Central Asia Post-combustion stage of Analytical CCT Review Miroslav Walis Enprima Engineering Ad Hoc Group of of Experts on on Coal in in Sustainable Development, 7 th th Session Geneva 7-8 December 2004

2 Capacity Building for for Air Air Quality Management and and Application of of Clean Coal Technologies in in Central Asia Post-combustion stage Chapters: An overview of of the the country characteristics of of the the byproducts of of combustion in in Central Asian coal-fired power plants by- An economic assessment of of the the capture and and use use of of these by- by-products Suggested local markets for for use use of of the the combustion by- by- products

3 REGION AND COUNTRY CHARACTERISTICS: Central Asia: -Kazakhstan, Uzbekistan, Kyrgyzstan, Tajikistan, Turkmenistan SHARE OF OF TOTAL PRIMARY ENERGY SUPPLY/ COUNTRIES OF OF CENTRAL ASIA/ 2001: Table Table 1 Kazakhstan: Uzbekistan Kyrgyzstan Tajikistan Turkmenistan Total (ktoe) Out of that (in %): - Coal: 52,3 1,8 13,3 1,8 00,0 - Gas: 21,7 83,3 24,5 16,9 74,2 - Hydro: 1,7 1,0 44,7 41,4 00,0 - Oil: 24,1 13,9 17,4 41,4 25,8

4 Coal as the fuel-source for energy generation Coal as as the the fuel-source for for energy generation Important role role in: in: --Kazakhstan -Kyrgyzstan -Uzbekistan Small importance: --Tajikistan No No importance: -Turkmenistan Therefore: Concentration on on the the power sector in in Kazakhstan, Kyrgyzstan, Uzbekistan and Tajikistan, only only

5 1. KAZAKHSTAN 1. KAZAKHSTAN Third largest in in the the FSU FSU (after Russia and and Ukraine) Installed capacity of of around 18,000 MW: 15,700 MW MW in in steam-electric plants, and and the the balance in in hydroelectric plants; In In power plants produced billion kilowatt-hours of of energy, (9% (9% more than in in 1999 and and 5% 5% more than in in 1998); In In domestic production was was up up 7.3% to to TWh and and consumption was was up up 4.2% to to TWh.

6 1. KAZAKHSTAN (continuing) 1. KAZAKHSTAN (continuing) Electricity imports -- sharply at at TWh (an (an increase of of 20.3% from 2000); In In 2002 Power Grid Grid became a surplus power supply system for for the the first first time; Electricity production increased from 2001 to to 2002 by by 5.3%; Demand for for electricity in in Kazakhstan in in 2002 increased by by 2.5% from the the year year 2001 Electricity imports fell fell by by half half--from 2,95 2,95 billion kw/h in in 2000 to to billion kw/h in in 2001

7 1.1. CHARACTERISTIC OF POWER GENERATION SECTOR - COAL DEPOSITS Major coal coal producer; with with reserves of of about 37.5-bil tons annual coal coal production now now amounts to to about mil mil tons The The most important coal coal resources: Ekibastuz (the (the third largest coal coal basin in in the the FSU), and and the the largest mining company in in this this area area is is Bogatyr Access Komir The The Bogatyr mine is is one one of of the the world s largest (and has has produced over a billion tons of of coal) Maikuben-Vest mine Vostochny open cast cast mine in in the the Pavlodar region

8 1.1. CHARACTERISTIC OF POWER GENERATION SECTOR COAL DEPOSITS --continuation Annual coal coal production: about mil. mil. tons coal coal sold sold to to local power plants and and exported to to Russia Coal exports to to Russia have been significant but but there are are longrunning disputes on on cost, quality, and and delivery issues. In In partial settlement of of these disputes, the the Russian utility -- Sverdlovskenergo acquired: two two mines near Ekibastuz in in 1996

9 THERMAL POWER PLANTS; GENERALLY Thermal power plants produce the dominant share of electricity (and hydroelectric plants produce the remainder); The established national power industry capacity totals 18.2 thousand MW; The structure of the electric power output falls into the following elements, depending on the energy source: coal-powered plants (70.3 % of the total) gas-fuel oil-powered plants (17%) hydroelectric plants (12%) nuclear power plants (0.7%)

10 THERMAL POWER PLANTS; GENERALLY - continuation The The generation of of electric power in in Kazakhstan decreased faster than the the demand reduction In In 1993 the the domestic production totaled billion kwh, while Kazakhstan needed billion kwh of of electric power --the the deficit being billion kwh. Forty-six of of Kazakhstan's coal/petroleum-fired plants supply electricity, heating, and and hot hot water to to nearby residences and and industries during the the winter. The The remaining eight coal // petroleum-fired plants, the country's largest generating facilities, are devoted solely to to electricity production

11 THERMAL POWER PLANTS; GENERALLY - continuation Heated power plants generate 84.7% of of power in in Kazakhstan. They account for for three fourth of of the the heat heat produced nation-wide Individual boiling houses contribute more than one one fourth The largest portion of of power and heat is is produced by by the heated power plants of of Pavlodar and Karaganda regions (add 56.2% and and 37.8% in in the the nation-wide volume of of power generation)

12 COAL POWER GENERATING CAPACITIES; AND OWNERS The The country's installed capacity base is is heavily centralized with with 7,400 MW MW of of thermal capacity at at just just two two sites: Ekibastuz-1 (8 (8 X MW) Ekibastuz-2 (2 (2 X MW) Ermakov (8 (8 X MW). There are are combined heat heat and and power (CHP) plants of of which are are in in urban or or suburban locations (and 8 hydroelectric plants). The The thermal power plants use use coal, oil, oil, and and gas, gas, but butbrown coal from the Ekibastuz basin is is the dominant fuel source with a 75% share, followed by by natural gas gas at at 14% 14% and and oil oil at at 11% 11%

13 POWER PLANTS, CAPACITIES, LOCATION, AND MAIN OWNERSHIP STRUCTURE The The U.S. U.S. power company AES Corp. acquired Ekibastuz-1 in in August 1996 (8 (8 X 500 MW). Ekibastuz-1 has has appr. 25% 25% of of Kazakhstan's total installed power-generating capacity. In In fall fall of of 1997, AES purchased four four combined heat heat and and power stations and and won won concessions on on two two hydroelectric stations in in East Kazakhstan region, with with a combined total capacity of of more than 1,300 megawatts. Ekibastuz-2 has has been under intermittent construction for for years and and has hastwo 500 MW sets sets in in operation. It It is is run run by by a state-owned company.

14 POWER PLANTS, CAPACITIES, LOCATION, AND MAIN OWNERSHIP STRUCTURE --continuation Ermakov (8x300 MW) --owner Eurasian Energy Corp. (EEC jointly owned by byjapan Chrome Corp (65.67%), the the Kazakh government (24.33%), and and company employees (10%)). APC has 1,239 MW of of electric capacity and and 3,975 Gcal of of heating capacity. Annual production is is about 4,500 GWh of of electricity. It It has has three CHP plants in in Almaty ATETS-1(173 MWe), ATETS-2 (145 MWe), and ATETS-3 (290 MWe) Ispat-Karmet JSC took over the the running of of the the thermal power plant Karagandinskaya TEZ-2. The Kazakhmys corporation currently includes the the Zhezkazganskaya and and Balkhashskaya thermal power stations, the the Karagandinskaya GRES-2.

15 POWER PLANTS, CAPACITIES, LOCATION, AND MAIN OWNERSHIP STRUCTURE --continuation Kaztzink JSC includes the the Tekely power complex. Kazakhstan and and Russia: an an agreement -- Russia's UES to to receive a 50% in in the the Ekibastuz State Regional Power Station 2 in in Pavlodar--the last last power station not not to to be be privatized.

16 2. UZBEKISTAN 2. UZBEKISTAN Currently the the largest electricity producer among the the Central Asian republics, and and a net net exporter of of electricity; Total installed generation capacity of of 11,283 MW; MW; Achieved self-sufficiency in in energy after gaining independence in in 1991; Maintenance of of its its power systems has has deteriorated and and as as a result --generating units have ceased operation; Much of of the the equipment in in generation, transmission and and distribution systems is is outdated and and extremely inefficient; According to to some estimates (at (at the the current rate rate of of energy production and and consumption) the the demand for for power would exceed the the projected production by by percent in in 2010.

17 2.1. CHARACTERISTIC OF POWER GENERATION SECTOR - COAL DEPOSITS The The installed capacity 11,200 MW; comes from power plants, (including thermal power plants with with a total capacity of of 9,800 MW MW and and hydroelectric power stations with with a total capacity of of 1,400 MW); There are are no no nuclear power plants in in Uzbekistan; Electricity derived primarily from thermal plants with with85 85 percent of ofthermal plants powered by bynatural gas, 8 percent by by heavy oil oiland 7 per cent by by coal; The The most significant coal-powered facilities are are two power plants in in the the vicinity of of the the Angren mine near Tashkent, one one that that is is Novo-Angren (2,100 MW); Uzbekistan produces approximately 48,000 GWH of of electricity annually with with almost all all electricity consumed domestically. Only about 1,000 GWH of of electricity are are exported to to the the neighboring countries (Tajikistan and and Kyrgyzstan)

18 2.1. CHARACTERISTIC OF POWER GENERATION SECTOR --COAL DEPOSITS -- continuation billion kwh of of electric power generated by by enterprises of of Uzbekenergo state joint-stock company; Heat generating plants of of industrial enterprises and and small hydroelectric power stations, (under the the Ministry of of Agriculture and and Water Management) produced the the remainder; Production of of electric power at at general-use thermal power plants was was reduced by by percent or or billion kwh, at at general-use hydro power stations and and block stations -- increased by by percent to to billion kwh; Uzbekistan is is part part of of the the United Central Asia Power System (CAPS); A decree on on partial privatization, de-monopolization and and deregulation of ofpower engineering and andcoal coalmining industries issued.

19 2.1. CHARACTERISTIC OF POWER GENERATION SECTOR - COAL DEPOSITS - continuation The The Ministry of of Power Energy has has been transformed into into the the Uzbekenergo State Joint-stock Company.; Major power stations and and electric grids also also transformed into into joint-stock companies, and and partially offered to to the the foreign investors.; However, Uzbekenergo still still holds the the control shares of of those companies.

20 3. KYRGYZSTAN 3. KYRGYZSTAN Suffered from a financial and and technical deterioration of of the the power system; Power transmission capacities are are used almost to to the the full, full, especially during peak time time in in the the heating season; From 1991 to to 1998, technical and and commercial losses increased by by more than 4 times and and stood at at per per cent cent of of total electricity supply in in 1998; Rich in in hydroelectric potential estimated at at 26,000 MW MW with with an an energy content of of 10,000 GWh in in a seasonally normal year. Only about 10% 10% of of this this has has been developed; Its Its coal coal reserves estimated at at billion tones; costly to to mine and and only only reserves of of million tons have been developed; Thus imports of ofcoal, oil oil and and natural gas; gas; and and exports electricity.

21 3. KYRGYZSTAN - continuation 3. KYRGYZSTAN - continuation Electricity exports are are mostly to to Kazakhstan and and partly to to Tajikistan and and Uzbekistan; A small export of of about 5 GWh to to China through a kv kv line line commenced in in 1993; Power system is is a part part of of the the Central Asian Integrated System to to which it it provides reserve capacity; The The country is is fully fully electrified; Total generation and and domestic sales in in 2000 and and 2001 were about the the same as as in in 1990, though the the volumes of of exports have declined; During this this period the the consumption mix mix has has undergone a major change. The The share of of industrial consumption declined from 45.2% to to 14.3%, while that that of of residential consumers went up up from 14.5% to to 54.6%

22 3.1. ELECTRICITY GENERATION AND SALES IN KYRGYZSTAN (IN GWH) Year Gross generation 13,155 12,860 14,844 13,728 Of which: Hydro: 8,953 11,720 13,635 12,444 Thermal: 4,202 1,140 1,210 1,284 Total Net sales 11,622 10,336 10,615 9,152 Of which: Exports-net 3,978 2,505 2,833 1,982 Domestic sales 7,644 7,830 7,782 7,169 Total System Losses 1,538 2,524 4,229 4,576 Total System Losses (%) Peak demand went up from 1,590 MW in 1990 to 2,173 MW in Presently it is estimated at 2,700 MW. Defined as the difference between the gross generation and the billed sales, in GWh.

23 3.2. STRUCTURAL DEVELOPMENT 3.2. STRUCTURAL DEVELOPMENT After separation from the the Soviet Union: Kyrgyzenergo (State Electric Company) was was formed in in April 1992 to to own own and and operate the the electricity and and district heat heat systems; Early in in 1994 it it was was renamed as as Kyrgyz National Energy Holding Company (KNEH) and and operated till till 2001 as as a state owned vertically integrated national utility; In In 2001, Kyrgyzstan embarked on on a restructuring of of Kyrgyzenergo, splitting off off the the company's distribution networks and and leaving the the former monopoly as as just just an an electricity generating company; Four joint-stock companies Sever Elektro, Vostok Elektro, Osh Elektro, and and Dzhalalabad Elektro--were created from Kyrgyzenergo

24 SYSTEM DIMENSIONS AND CHARACTERISTIC/ ENERGY GENERATED FROM COAL Power system is is relatively small; Installed generation capacity of of 3,532 MW consisted of of hydroelectric stations (2873 MW) and andtwo combined heat and power thermal plants (659 MW) at atbishkek and and Osh. These are are burning bituminous coal/ anthracite.

25 4. TAJIKISTAN 4. TAJIKISTAN Coal reserves surpass those of of oil oil and and gas; gas; Proven deposits of of coal are are estimated to to hold billion tons of of coal; Most of of coal coal mining sites are are located in in hard-to-reach mountainous areas (what makes industrial development not not feasible); Its Its declining coal coal production (20,700 tons in in 2000) meets fully fully the the country's declining coal coal demand and and leaves 50% of of the the production for for export.

26 4.1. SYSTEM DIMENSIONING AND CHARACTERISTIC 4,400 MW of of installed electricity generation capacity consisting of: of: seven large hydroelectric stations with with a total of of 4,052 MW; and and two two fossil fuel fuel fired thermal plants at at Dushanbe and and Yavan with with total total capacity of of about MW MW Tajikistan also also exports electricity to to the the southern areas of of Kazakhstan, mainly in in summer; The The volume of of exports and and imports vary vary as as a function of of water availability (see (see next next Table).

27 TAJIKISTAN'S EXPORTS AND IMPORTS OF ELECTRICITY (GWH) Item Item Generation 18,200 18,200 14,800 14,800 15,797 15,797 14,247 14,247 Exports 5,700 5,700 4,200 4,200 3,831 3,831 3,901 3,901 Imports 6,900 6,900 4,900 4,900 3,641 3,641 5,242 5,242 Available for for domestic market market 19,400 19,400 15,500 15,500 15,607 15,607 15,580 15,580

28 CHAPTER 2 POST-COMBUSTION CLEAN COAL TECHNOLOGIES SOLUTIONS PROPOSAL ALL COUNTRIES OF CENTRAL ASIA

29 GENERAL Post-combustion clean coal solutions shall in in a complex --include: Measures for for increase efficiency of of dust elimination after burning process; what means implementation of of high efficient electroprecipitators after the the boilers, to to reach the the dust dust removal efficiencies around 99,5 99,5 % (and higher); Measures for for reduction of of SO2 SO2 concentrations in in flue flue gas; gas; what means implementation of of flue flue gas gas desulphurization process-technology after the the burning process; Measures for for NOx NOxreduction (secondary measures), using catalytic de-nox process technology; Possibilities for for the the further safe safe utilization of of postcombustion by-products (fly (fly ash/ ash/ bottom ash; ash; gypsum/ stabilizate, etc.) etc.)

30 GENERAL - continuation GENERAL - continuation Due Due to to the the specific conditions, further solution proposals do do not consider: measures for for NOx NOxreduction (primary or or secondary measures --be be a part part of of combustion phase ), and and no no speculations on on any any systems for for secondary de-nox program done in in this this stage (these always applied after the the application of of primary de-nox measures); Dust elimination measures not not discussed --technical solution is is well well know and and widely available. The The dust dust elimination program has has always to to be be applied prior any any de- de- NOx NOxand de-sox technologies. The The target of of this this Study can can not not be be a definition the the country s clean coal coal solution policy, or or program; Nevertheless the the implementation of of post-combustion clean air air measures will will have to to be be under respective countries government responsibility perhaps in in a form of of Country Clean Coal Air Air Act.

31 FLUE GAS DESULPHURIZATION PROCESS THE WAY HOW TO REDUCE SULPHUR IN IN FLUE GASES DESULPHURIZATION METHOD: Due Due to to boiler capacities and and coal coal parameters predominantly the the wet limestone desulphurization process technology shall be be applied; The The main advantages of of wet wet limestone process: Simple and and reliable process; commercial accessibility; available references; very very good performance and and consumption figures; end end product gypsum, or or stabilizate is is a stable substance safely and and easily to to be be stored, deposited, and/ and/ or or further commercially utilized Investment costs for for FGD implementations constantly decrease due due to to many proven applications worldwide

32 WET FLUE GAS DESULPHURIZATION PROCESS FEATURES; simplified To To provide needed operation flue flue gas gas pressure (flue gas gas fans fans for for each boiler block shall usually replace the the old old fans); Flue Flue gas gas enters the the absorber via via collecting duct. (Old (Old stack enables to to by-pass the the extra flue flue gases in in case of of bigger flue flue gas gas load load than given by by the the contract, or or at at emergency conditions); Limestone powder unloaded on on the the railway siding (or (or truck unloading pit), pit), and and stored in in a silo; silo; or orlump limestone to to be be crushed and and milled in in the the own own mills; Reaction of of limestone slurry with with counter-flow of of raw raw flue flue gas gas (reaction results in in obtaining of of gypsum slurry composition in in re-circulated slurry); The The bleed gypsum slurry is is being dewatered on on batteries of of hydro-cyclones and and belt belt filters, or or on on centrifuges De-watered gypsum transport into into gypsum storage house and and from there into into a mixing center

33 WET FLUE GAS DESULPHURIZATION PROCESS FEATURES; simplified cont. Complete auxiliary units, as as process water preparation, oxidation air air system, etc., etc., are are also also included in in the the supply for for FGD Project; End End product --gypsum --stabilized by by adding of of ash ash and and lime lime is is ecologically safe safe and and stable product. (usually outside the the supplier s battery limit); Cleaned flue flue gas gasleaves the the absorber through gas-gas heater (where clean flue flue gas gas is is heated-up to to pass the the stack), or or via via wet wet stack, or or via via cooling towers; Desulphurization efficiency has has to to be be designed to to cope with with by by valid country Clean Air Air Law Law (efficiency normally as as %, %, and and concentration of of sulfur oxides in in cleaned flue flue gas gas under mg/ mg/ Nm3).

34 PRESUMPTIONS FOR SPECIFIC PROCESS/ PRODUCTS DIMENSIONING the the future retrofits of of existing power plants boilers may may include approximately 20% 20% of of these capacities converted to to fludized bed bed technology; within the the term from 2007 to to (see (see specifically for for respective countries); therefore the the rest restcapacities may may ask ask for for flue flue gas gas desulphurization (FGD) solutions; brown coal coal having heat heat value from to to kj/kg; H2O H2O content (Wtr) around % mass; Sd Sdcontent in in orig. sample approximately 1,2 1,2 % mass; flue flue gas gas flow flow rate rate (used for for an an estimates of of required capacities of of FGD applications) set set as as some type type of of the the nominal value will will be: be: for for brown brown coal: coal: Nm3/h Nm3/h per per one one of of MWe MWemodule of of electricity production (dry (dry status, status, 6% 6% O2, O2, normal conditions), for for hard hard coal: coal: Nm3/h Nm3/h per per one one of of MWe MWemodule of of electricity production (dry (dry status, status, 6% 6% O2, O2, normal conditions),

35 PRESUMPTIONS FOR SPECIFIC PROCESS/ PRODUCTS DIMENSIONING - continuation considered is is SO2 concentration at at the FGD outlet on on 500 mg/nm3 (at (at limestone reactivity of of 97%); FGD plants delivered as as turn-key supplies; FGD nominal concept: 1 absorber per per each MWe production block; 1 limestone acceptance and and 1 limestone slurry preparation unit unit common for for 2 absorbers (where possible); 2 dewatering lines per per one one MWe de-sulphurized capacity; no no milling and and crushing plants considered (powder limestone to to be be procured from central milling source; no no gypsum deposit areas preparation considered in in this this Study);

36 PRESUMPTIONS FOR SPECIFIC PROCESS/ PRODUCTS DIMENSIONING - continuation The The owners ordering (prior the the projects starts) the the owner s engineering; FGDs are are to to be be of of state-of--art technical level; investment costs are are forecasted on on a presumption that that full full engineering, all all mechanical/ electric/ I I + C supplies, and and 70% 70% of of civil civil and and erection work, and and full full commissioning and and documentation is is to to be be delivered by by abroad companies; Price/ costs level for for equipment based on on Central Europe price level of of 2004, and and inflation rate rate forecast be be 5% 5% annually; FGDs implementation schedule proposed for for as as maximum years (for (for total number of of desulphurized sources), depends on on a country see see further; No No financing possibilities/ sources/ instruments discussed in in this this place

37 TECHNICAL SCOPE AND SPECIFICATION OF SERVICES RELATED TO FGD IMPLEMENTATIONS Engineering; like like Civil permit release design, Basic design, Detail design (all (all for for civil, process, mechanical, electro and and instrumentation part), Manufacturing and and As-built design; Procurement of of components, works and and services: Complete civil civil part; part; Absorber units units with with spray spray header header system; steel steel flue flue gas gas duct duct system; supporting steel steel structures; induced draft draft fans fans (and/ (and/ or or booster fans); fans); process tanks; tanks; process piping; piping; process and and recirculation pumps; valves; insulation of of ducts ducts and and tanks; tanks; re- limestone unloading unit; unit; silo silo for for limestone storage (including the the de-dusting and and fluidization); hydro-cyclone batteries (or (or centrifugal units); units); de-watering filters; filters; discharge, distribution and and storing of of gypsum in in a gypsum store; store; isolation and and by-pass dampers; expansion joints; joints; agitators, etc.; etc.; stabilizate mixing mixing units; units; Gas/ Gas/ gas gas heaters, or or wet wet stack, stack, or or inlets inlets into into existing cooling towers;

38 TECHNICAL SCOPE AND SPECIFICATION OF SERVICES RELATED TO FGD IMPLEMENTATIONS -- continuation Electro-part supply, as as HV/ HV/ LV LV motors, trafos, trafos, switchboards, MCCs, MCCs, cables, etc.; etc.; Instrumentation and and Control part part supply, including Fanuc Fanuc control system, field field instrumentation, cabling, analyzers, etc.; etc.; Mechanical erection for for the the mechanical equipment (scope and and spec. see see above); Erection of of electro and and I&C, I&C, parts, including the the cable work, energizing, inspection (scope and and spec. see see above); Project management; for for the the full full Project scope; Commissioning and and test test run run of of the the civil, mechanical, electro and and I&C I&C part; as as well well as as warranty testing; Training for for all all equipment and and disciplines; Warranty service

39 IMPLEMENTATION KEY TERMS AND DURATIONS IMPLEMENTATION KEY TERMS AND DURATIONS As As a typical FGD project implementation schedule in in months (key (key points only; valid for for implementation of of 1 FGD project of of size size MWe of of electrical output): The The Contract signature day.day 0 Site Site opening (month) Start of of civil civil work Finish of of civil civil work Start of of mechanical erection Finish of of mechanical erection First flue flue gas-in into into FGD plant FGD Trial run run start Take-over/ hand-over of of FGD plant

40 FGD BASIC IMPLEMENTATION PLAN; BASED ON COUNTRIES INPUT DATA AND CONDITIONS; BY COUNTRIES --KAZAKHSTAN Brown coal coal (lignite) fired power capacities; totally installed MWe; Based on on the the only only available data, next next are are the the basic proposals for for implementation of of post-combustion clean coal coal technologies. These are are proposed in in this this stage for for only only those brown coal coal (lignite) fired power capacities of of totally MWe. Total capacity to to be be desulphurized: MWe Average generated volume of of flue flue gases subject to to gas gas cleanup (FGD wet wet limestone process); presumptions see see above: Nm3/h (as (as a final final status in in 2022) up

41 FGD BASIC IMPLEMENTATION PLAN; BASED ON COUNTRIES INPUT DATA AND CONDITIONS; BY COUNTRIES --KAZAKHSTAN --continuation Estimated total sulfur removal rate rate (at (at a final final stage --in in 2022): to to ton/ ton/ hour (what means up up to to ton ton of of sulfur removal per per year, considering operation days a year); Estimated production of of gypsum (at (at a final final stage --in in 2022): to to ton/ ton/ hour (what means up up to to ton ton of of gypsum per per year, considering operation days a year); Estimated number of of nominal FGD production blocks: (Note: nominal FGD see see in in Presumptions); (no (no any any specific conditions of of individual power plants taken into into account, as as f.e. f.e. power blocks design/ magnitude, owners structures/ intentions, etc.);

42 FGD BASIC IMPLEMENTATION PLAN; BASED ON COUNTRIES INPUT DATA AND CONDITIONS; BY COUNTRIES -- KAZAKHSTAN -continuation Estimated overall direct investment costs for for FGDs (only): mil. mil. EUR (spent during the the period of of 2007 to to 2022). Other related costs: planning stage/ basic land land preparation: 7 mil. mil. EUR owners engineering costs: mil. mil. EUR Estimate of of total investment costs from 2007 till till 2022: mil. mil. EUR/ for for KAZAKHSTAN

43 FGD BASIC IMPLEMENTATION PLAN; BASED ON COUNTRIES INPUT DATA AND CONDITIONS; BY COUNTRIES --UZBEKISTAN Brown coal coal (lignite) fired power capacities; totally installed MWe. Based on on the the available data; only only for for brown coal coal (lignite) fired power capacities of of totally MWe. Total capacity to to be be desulphurized: MWe Average generated volume of of flue flue gases subject to to gas gas cleanup (FGD wet wet limestone process); presumptions see see above: Nm3/h (final status at at 2017) Estimated total sulfur removal rate rate (at (at a final final stage --in in 2017): to to ton/ ton/ hour (what means up up to to ton ton of of up sulfur removed every year, considering operation days a year);

44 FGD BASIC IMPLEMENTATION PLAN; BASED ON COUNTRIES INPUT DATA AND CONDITIONS; BY COUNTRIES UZBEKISTAN --continuation Estimated production of of gypsum (at (at a final final stage --in in 2017): 66,5 66,5 to to ton/ ton/ hour (what means up up to to ton ton of of gypsum per per year, considering operation days a year); Estimated number of of nominal FGD production (or (or reaction) blocks: (Note: nominal FGD production unit unit means the the unit unit treating Nm3/h inlet inlet flue flue gases, having the the parameters as as in in the the Presumptions) 4 (no (no specific conditions of of individual power plants taken into into account, as as f.e. f.e. power blocks design/ magnitude, and and owners structures/ intentions, etc.);

45 FGD BASIC IMPLEMENTATION PLAN; BASED ON COUNTRIES INPUT DATA AND CONDITIONS; BY COUNTRIES UZBEKISTAN --continuation Estimated overall direct investment costs for for FGDs (only): mil. mil. EUR for for the the period of of 2007 to to Other related costs: planning stage/ basic land land preparation: 4 mil. mil. EUR owners engineering costs: 8 mil. mil. EUR Estimate of of total investment costs from 2007 till till 2017: mil. mil. EUR/ for for UZBEKISTAN

46 FGD BASIC IMPLEMENTATION PLAN; BASED ON COUNTRIES INPUT DATA AND CONDITIONS; BY COUNTRIES --KYRGYZSTAN Hard coal coal (lignite) fired power capacities; totally installed MWe; Based on on the the available data; proposed in in this this stage for for those hard coal coal fired power capacities of of totally MWe; Total capacity to to be be desulphurized: MWe Average generated volume of of flue flue gases subject to to gas gas cleanup (FGD wet wet limestone process); presumptions see see above: Nm3/h (final status at at 2012); Estimated total sulfur removal rate rate (at (at a final final stage --in in 2012): 4,4 4,4 ton/ ton/ hour (what means ton ton of of sulfur removed every year, considering operation days a year); up

47 FGD BASIC IMPLEMENTATION PLAN; BASED ON COUNTRIES INPUT DATA AND CONDITIONS; BY COUNTRIES KYRGYZSTAN --continuation Estimated production of of gypsum (at (at a final final stage --in in 2012): ton/ ton/ hour (what means ton ton of of gypsum per per year, considering operation days a year); Estimated number of of nominal FGD production (or (or reaction) blocks: 1 (no (no specific conditions of of individual power plants conditions taken into into account); Estimated overall direct investment costs for for FGDs (only): mil. mil. EUR for for the the period of of 2007 to to 2012 Other related costs: planning stage/ basic land land preparation: 2 mil. mil. EUR owners engineering costs: 2 mil. mil. EUR Estimate of of total investment costs from 2007 till till 2012: mil. mil. EUR/ for for KYRGYZSTAN

48 FGD BASIC IMPLEMENTATION PLAN; BASED ON COUNTRIES INPUT DATA AND CONDITIONS; BY COUNTRIES --TAJIKISTAN Hard coal (lignite) fired power capacities; totally installed MWe. Based on on the the available data; the the basic proposals for for implementation of of post-combustion clean in in this this stage for for those hard coal coalfired power capacities of of totally MWe; Total capacity to to be be desulphurized: MWe Average generated volume of of flue flue gases subject to to gas gas cleanup (FGD wet wet limestone process); presumptions see see above: Nm3/h (final status at at 2012) Estimated total sulfur removal rate rate (at (at a final final stage --in in 2012): 3,8 3,8 ton/ ton/ hour (what means ton ton of of sulfur removed every year, considering operation days a year); up

49 FGD BASIC IMPLEMENTATION PLAN; BASED ON COUNTRIES INPUT DATA AND CONDITIONS; BY COUNTRIES TAJIKISTAN --continuation Estimated production of of gypsum (at (at a final final stage --in in 2012): ton/ ton/ hour Estimated number of of nominal FGD production (or (or reaction) blocks: (Note: nominal FGD production unit; see see in in the the Presumptions) 1 (no (no specific conditions of of individual power plants conditions taken into into account); Estimated overall direct investment costs for for FGDs (only): mil. mil. EUR for for the the period of of 2007 to to 2012 Other related costs: planning stage/ basic land land preparation: 2 mil. mil. EUR owners engineering costs: 2 mil. mil. EUR Estimate of of total investment costs from 2007 till till 2012: mil. mil. EUR/ for for TAJIKISTAN

50 ESTIMATED MAIN INPUT, PROCESS, AND PRODUCTION PARAMETERS OF FGD APPLICATIONS IN INCOUNTRIES OF CENTRAL ASIA (Coal Burning Power Stations) Kazakhstan Uzbekistan Kyrgyzstan Tajikistan Total coal burning power/ heat plant capacities (2003) brown coal/ lignite -MWe Total coal burning power/ heat plant capacities (2003) hard coal

51 BY-PRODUCTS; UTILIZATION; TYPES; SPECIFICATION; PARAMETERS Bottom ash: ash: The The solid phase consisting mainly from Si02 Si02 and and Al2O3; Containing to to 45% 45% of of water; Normally expedited in in wet wet status or or directly from hoppers; Producers normally guarantee extraction limits and and mass activity 226Ra (not (not to to exceede the the locally set set standard for for radiation protection)

52 USE OF BOTTOM ASH AS A WINTER ROAD MAINTENANCE MATERIAL; POSSIBLE STANDARD DEMANDS Ar Ba Be Cr Cd Co Cu Ni Pb LIMIT VALUES OF EXTRACTIVITY max. acceptable concentration (mg/l) 0,10 2,00 0,005 0,1 0,02 0,1 1,00 0,50 0,50 Hg V Zn Fluorides Sulfites PAU + Conductivity * ph * (ms/m) max. acceptable concentration (mg/l) 0,005 0,20 3,00 1,50 300,00 0, ,00 5,5 11,0

53 BY-PRODUCTS; UTILIZATION; TYPES; SPECIFICATION; PARAMETERS cont. Fly Fly ash/ ash/ Characteristic: The The solid phase has has a granulometry 0 to to 1000 mm. mm. Mass of of repose to to kg/m3. Chemically inert material, composition mainly SiO2 a Al2O3; rest restcarbon max. 1% 1% mass (Fly (Fly ash ash must not not contain any any disvaluating impurities as as bottom ash, ash, clay, stones, brick parts, wooden parts, metal particles, etc). etc).

54 BASIC (typical) PHYSICAL AND CHEMICAL PROPERTIES OF FLY ASH (from lignite); FOR A USE INTO CONCRETES Loss by heating-up Content of free CaO SO3 content Cl- content % mass. % mass. % mass. % mass. max. 5,0 max. 1,0 max. 3,0 max. 0,1 Fly ash granulometry rest on sieve 0,045 mm % mass. max. 40 Index of effectivess after 28 days Volume stability Specific mass % Mm kg.m-3 min. 80 max Value of mass activity 226Ra Bq.kg-1 120

55 BY-PRODUCTS; UTILIZATION; TYPES; SPECIFICATION; PARAMETERS cont. Gypsum/ typical physical-mechanical properties: Gypsum is is di-hydrate of of calcium sulfite (CaSO4.2H2O), gained as as by-product at at wet wet limestone desulphurization process; Contains particles of of fly fly ash ash from flue flue gas gas and and minerals from limestone used in in FGD process. 1) 1) :at :at average average gypsum gypsum humidity humidity % mass: mass: 1 Properties Unit Found value Specific mass of wet freely spilled gypsum kg.m ) Granulometry rest on sieve 63 µm % mass

56 PHYSICAL AND CHEMICAL PROPERTIES --usually guaranteed --GYPSUM 1) humidity at loading in power stations; 2)in dry sample Properties Unit Guarantee value Humidity % mass ) ph value 5 8 CaSO 4.2H 2 O content % mass. min ) SO 3 content % mass. min. 41,8 2 ) MgO content % mass. max. 0,2 2 ) Chlorides content % mass. max. 0,1 2 ) Fluorides content % mass. max. 0,4 2 ) Alcalic substances content (Σ Na 2 O+K 2 O) % mass. max. 0,5 2 ) Evaluation of content of natural radionuklcledes - Mass radioactivity Ra 226 Bq.kg -1 max. 25

57 BY-PRODUCTS; UTILIZATION; TYPES; SPECIFICATION; PARAMETERS cont. Stabilizates: Stabilizate is is a civil civil industry substance; produced in in mixing centers; from coal coal burning process and and byproducts from FGD, adding lime lime and and mixing water; Possibility to toproduce civil civil stabilizate mixtures acc. acc. to to various prescriptions; Gypsum from FGD process and and bottom ash ash can can be be added into into by- stabilizate; After stabilizate curing (long-time lasting stabilization process) the the material --stabilizate is is significantly different by by it s it s technical parameters to to the the originally untreated products. Stabilizate has has favorable ecological properties

58 SOME TYPICAL PROPERTIES OF STABILIZATE FOR VARIOUS USE Properties Unit Value Volume mass of freely poured mixture, wet Kg.m Volume mass of wet mixture after compacting Kg.m Volume mass of dry substance after compacting Kg.m

59 BY-PRODUCTS; UTILIZATION; TYPES; SPECIFICATION; PARAMETERS cont. Microspheres/ Characteristic: Particular solid phase with with granulometry 0 to to m; m; particles of of ball ball form filled by by flue flue gas; gas; Having a high pouring density of of kg/m3; Chemically inert material, composition mainly SiO2 and and Al2O3; Good noise and and heat heat insulation properties; Temperature of of softening is is 1000 to to 1200 C. C.

60 SUGGESTED LOCAL MARKETS FOR BY-PRODUCTS SUGGESTED LOCAL MARKETS FOR BY-PRODUCTS Bottom ash: ash: For For building of of land land filling protection walls;as the the winter road/ pavement maintaining material;and for for the the production of of bricks-like products; Fly Fly ash: ash: In In a process of of poro-concrete production; for for production of of mortars, asphalt hydro-insulation strips, cement; it it use use to to be be certified Gypsum: Manufacturing of of gypsum plates; at at poro-concrete preparation; use use to to be be certified for for cement production (Gypsum must must not not contain any any disvaluating impurities as as bottom ash, ash, clay, clay, stones, brick brick parts, parts, wooden parts, parts, metal metal particles, etc). etc). Gypsum use use to to be be delivered in in wet wet form form (humidity 6 15% 15% mass). mass).

61 SUGGESTED LOCAL MARKETS FOR BY- PRODUCTS - continuation Stabilizates: Product in in compliance with with applicable local standards, various utilization in in civil civil industry use use to to be be certified as as a product for for countryside relief adjustments during the the cultivation work and and also also during asanation works of of deposit areas use use to to be be used for for sealing of of land-filling protection walls; as as a stabilizate for for road laying Stabilizate is is being delivered usually in in wet state directly from mixing centre silo Microspheres: As As material for for increase of of heat heat and and noise insulation product utilized also also under high temperatures. In In plastics in in automotive and and aircraft industry, into into tiles, floor covers, as as filling into into façade products, as as filling into into paints, etc. etc.