Steinmüller-Tagung 2013 23. 24. April 2013 Titel / title: Revamp and Retrofit of FGD Plants Vortragender / presenter: Dr. S. Binkowski Gummersbach, Germany 1
Employment Record Dr.-Ing. Stefan Binkowski since 02/13 2009-2013 2005-2009 2001-2005 Steinmüller Engineering GmbH, Gummersbach, Germany Department Manager Flue Gas Cleaning Process Steinmüller Engineering GmbH, Gummersbach, Germany Head of Flue Gas Desulphurization Department Steinmüller Engineering GmbH, Gummersbach, Germany Process Engineer Flue Gas Cleaning Lehrstuhl Umwelttechnik, Fachbereich Chemietechnik, Universität Dortmund, Germany, Dr.-Ing. (PhD) 2001 Graduation - Universität of Dortmund, Germany, Dipl.-Ing. (M.Sc. Chemical Engineering) 2
Steinmüller Engineering FGD Portfolio Consulting / Engineering - Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom) - Training of Eskom FGD Engineers Engineering / Optimisation / Supply - Amsterdam Hemweg Optimization (Nuon) - Owensboro Tray Revamp (OMU) Supply / New Built - Paroseni Retrofit Absorber Process Engineering and Main Components (LAB/CNIM) 3
Steinmüller Engineering FGD Portfolio Consulting / Engineering - Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom) - Training of Eskom FGD Engineers Engineering / Optimisation / Supply - Amsterdam Hemweg Optimization (Nuon) - Owensboro Tray Revamp (OMU) Supply / New Built - Paroseni Retrofit Absorber Process Engineering and Main Components (LAB/CNIM) 4
Medupi 6 x 800 MW FGD Concept and Basic Engineering Tutuka 6 x 600 MW 5
Medupi 6 x 800 MW FGD Concept and Basic Engineering 6
Medupi 6 x 800 MW FGD Concept and Basic Engineering One of the largest FGD systems in the world, 2 nd in South Africa 7
Medupi 6 x 800 MW FGD Concept and Basic Engineering Eskom Steinmüller Engineering: Project Management Services FGD Process Design FGD Plant Design Special Studies (e.g. Material, Water Saving, Technology Evaluation, Reagents Specification) Design Guidelines Development of Specifications Training Eskom Staff Skills Development Black and Veatch: Project Management Services Civil Engineering Steel Structure Layout Bulk Material Handling Special Studies Life Cycle Cost Estimation Risk Assessment Grid (LV, HV) Enquiry Specification Schedule Development 8
Steinmüller Engineering FGD Portfolio Consulting / Engineering - Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom) - Training of Eskom FGD Engineers Engineering / Optimisation / Supply - Amsterdam Hemweg Optimization (Nuon) - Owensboro Tray Revamp (OMU) Supply / New Built - Paroseni Retrofit Absorber Process Engineering and Main Components (LAB/CNIM) 9
FGD Engineering/Optimization Different approaches possible, depending on project: Optimizing gas flow distribution and gas-liquid contact - Nozzle type - Nozzle arrangement - Wall rings -Tray - CFD analysis Optimizing FGD operation - ph value - Number of operated pumps - Liquid level - Limestone injection point - Limestone quality Combination of above mentioned measures 10
Steinmüller Engineering FGD Portfolio Consulting / Engineering - Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom) - Training of Eskom FGD Engineers Engineering / Optimisation / Supply - Amsterdam Hemweg Optimization (Nuon) - Owensboro Tray Revamp (OMU) Supply / New Built - Paroseni Retrofit Absorber Process Engineering and Main Components (LAB/CNIM) 11
FGD Engineering/Optimization NUON Hemweg 8 680 MW built by ESTS / HTS in 1994 revamp by Steinmüller Engineering 2007 scrubber diameter ~18 m 12
FGD Engineering/Optimization NUON Hemweg 8 Objectives Increased removal efficiency without any increase in circulating flows or additional installations by more than 2 %-points Steinmüller Advanced Nozzle Positioning (ANP) uses customised spray bank layout and adapted current technical state of the art nozzles and piping system Implementation / Erection of new system Further process optimizations identified in additional study 13
Optimizing gas flow distribution ANP Advanced Nozzle Positioning New, optimized spray banks Better flow distribution 14
Optimizing gas flow distribution ANP Advanced Nozzle Positioning Effective use of secondary dispersion to increase surface for absorption and overall removal efficiency Upper opening of tangential nozzle Bright color of spray due to refraction indicates small droplets 15
Achieved efficiency improvement (3 of 4 levels in operation) 100 90 89,84 % 800 700 89.8 % SO 2 Removal Efficiency [%] Sump Level [m] 80 70 60 50 40 30 20 10 0 Removal Efficiency [%] Sump Level [m] SO2 2Inlet [ppm] SO2 2Outlet [ppm] Total Load [MW] 600 500 400 300 200 100 0 Concentration [ppmv] Load [MW] 10.2 % Emission 29 % 71 % 92.8 % SO 2 Removal 7.2 % Emission Efficiency [%] Sump Level [m] 100 90 80 70 60 50 40 30 20 10 0 92,78 % Removal Efficiency [%] Sump Level [m] SO2 2 Inlet [ppm] SO2 2 Outlet [ppm] Netto Load [MW] 800 700 600 500 400 300 200 100 0 Concentration [ppmv] Load [MW] 71 % Increasing the FGD removal efficiency by 2.9 % points means reducing the SO 2 emissions by nearly 30 % 16
Achieved efficiency improvement (3 levels) 100 80 60 Efficiency vs. L/G 2.9 % of increased efficiency by spray bank layout equals an L/G increase of 18.2 % (~380 kw)! 40 100 20 0 + 2.9 % 0 L/G 90 50.000 95 85 + 18.2 % 80 20.000 reduces auxiliary power (e.g. 0.38 MW x 7000 h/a x 55 /MWh 146 000 /a) increase usable coal range 0.6 % S 0.9 % S increase plant output for same SO 2 cap 17
Optimizing gas flow distribution Potential of wall ring installation Gas flow further homogenized Absorbens guided from wall back into scrubber Local increase of velocity and L/G Efficiency improvement by 0.5-0.8 %-points 18
Optimizing FGD operation Absorber liquid level vs. Number of pumps Increasing sump level will increase total L/G Removal efficiency increased by 2.1 %-points 19
Steinmüller Engineering FGD Portfolio Consulting / Engineering - Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom) - Training of Eskom FGD Engineers Engineering / Optimisation / Supply - Amsterdam Hemweg Optimization (Nuon) - Owensboro Tray Revamp (OMU) Supply / New Built - Paroseni Retrofit Absorber Process Engineering and Main Components (LAB/CNIM) 20
SESS WFGD Technology - Dual Flow Tray Absorber Dual Flow Tray Design Perforated Plate Ends Bent Up For Bolted Connections Dual Flow Tray Tower Perforated Plates Equidistant Hole Center Lines 21
Acid Gas Control - WFGD Dual Flow Trays Maximize mass transfer (e.g. SO 3, dust) Shorter absorber design 15-20 % lower Liquid/Gas ratio Access/Maintenance support grid Lower outlet emissions possible Scale-free operation at IPL Petersburg w/multiple trays since 1983 22
Owensboro Municipal Utilities - Elmer Smith Station Units 1 & 2 Owensboro Municipal Utilities Elmer Smith Generating Station Units 1 and 2 Owensboro, Kentucky Wet FGD System 1994 Startup Open Spray Tower Absorbers 2007 Upgrade w/ Dual Flow Trays HaRDE Precipitators 151 MW / 290 MW 23
Owensboro Municipal Utilities - Elmer Smith Station Units 1 & 2 Open Tower DFT Tower Startup 1995 Retrofit 2007 Number of Trays None One Gas Flow (Am 3 /h) 3,167,375 3,167,375 Inlet SO 2 (ppmv) 2,000 2,000 Outlet SO 2 (ppmv) 80 40 SO 2 Removal 96 % > 98 % Pressure Drop Increase (mbar) < 5 No other changes to operating system components or chemistry 24
Paroseni Absorber Retrofit Flue gas desulphurisation system for unit no. 4 of 150 MW el and hot water boiler of 103,2 Gcal/h 25
Steinmüller Engineering FGD Portfolio Consulting / Engineering - Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom) - Training of Eskom FGD Engineers Engineering / Optimisation / Supply - Amsterdam Hemweg Optimization (Nuon) - Owensboro Tray Revamp (OMU) Supply / New Built - Paroseni Retrofit Absorber Process Engineering and Main Components (LAB/CNIM) 26
Paroseni Absorber Retrofit Design Parameter Flue gas desulphurisation system for unit no. 4 of 150 MW el and Hot Water Boiler of 103,2 Gcal/h 27
Paroseni Absorber Retrofit Steinmüller Scope Supply of: Spray banks Recirculation pumps Agitators Oxidation air blowers Mist eliminators Emergency quench Process engineering for the wet FGD process 28
Steinmüller Engineering FGD Portfolio Consulting / Engineering - Medupi 6 x 800 MW FGD Concept and Basic Engineering (Eskom) - Training of Eskom FGD Engineers Engineering / Optimisation / Supply - Amsterdam Hemweg Optimization (Nuon) - Owensboro Tray Revamp (OMU) Supply / New Built - Paroseni Retrofit Absorber Process Engineering and Main Components (LAB/CNIM) 29
Steinmüller Engineering provides experienced consulting proven optimization concepts customized engineering solutions for your FGD. Thank you! 30