air quality control systems- technological solutions for...

Preeti Malhotra

19 November 2014

Air Quality Control Systems-Technological Solutions for Power

Sector

BAQ 14, Colombo

© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Presentation title - 17/11/2014 – P 2

REDUCING COST OF ELECTRICITY

More than 80 years of experience, optimising designs and strong R&D activities,

has led to robust and reduced operating cost including more

efficiency use of reagents and power consumption reduction

LOWERING ENVIRONMENTAL

FOOTPRINT

480 GW & 2800 systems Unrivalled AQCS supplied for both power and industry

sector worldwide

INCREASING FLEXIBILITY

& RELIABILITY

Innovative Modular Design For power and industry have elevated operational flexibility

and reliability to a new high level

Air Quality Control System (AQCS)



Market/Customer Drivers AQCS

Market Driver Customer Driver

• Local Environmental regulations

• Guidelines of financing

institutions

• Plant permitting requirements

• Public pressure

• CSR initiatives

• Environmental compliance

• Cost for environmental

compliance including CAPEX

and OPEX

• Fuel and operational flexibility

• Lead time



Product Portfolio for Power Plants Air Quality Control Systems



Over 480 GW supplied for power & 2,800 systems for industry globally

World’s No. 1 AQCS Supplier

North America

Power 148+ GW

Industry 200+ Systems

Latin America

Power 6+ GW


Russia & CIS

Power 11+ GW


Europe

Power 115+ GW

Industry 1,000+ Systems

Middle East & Africa

Power 35+ GW


India

Power 50+ GW


Asia

Power 95+ GW


Oceania

Power 20+ GW




Product Portfolio for Industry Air Quality Control Systems

I &S

DFGD (NID and SDA)

SWFGD

ESP (Wet and Dry)

FF (high ratio and low ratio)

SCR

WtE

Alu

Oil & Gas

P&P

Cement

HQT, WCD,

FDC, HPC;

Drypac

DAS/DSI

Industry Specific GTC

FTC

Alfeed

HEX

Polishing &

condensing

scrubber;

DAS

HQT : Hot Quenching Tower WCD: Water Cooled Ducts FDC: Forced Draft Cooler HPC: Hair Pin Cooler DAS: Dry Absorption System HEX: Heat Exchanger

ACI (Hg)



Global Footprint

Milan,

ITALY

Knoxville,

USA

Headquarters

Regional Execution Centre

Local Unit

R & D Centre

Paris,

FRANCE

Oslo,

NORWAY

Växjö,

SWEDEN

Wiesbaden,

GERMANY

Kolkata,

INDIA

Moscow,

RUSSIA

Beijing,

CHINA

Kobe,

JAPAN

Mexico City,

MEXICO

Global knowledge and resources, local presence and insight



R&D for Best-in-Class Technology

In-house pilot of absorption system

Extensive analytical laboratory services

Leading technology innovator of environmental control systems

• World’s largest in house

AQCS lab/test facility used

to:

• Develop new products,

• Advance existing products

• Utilises pilot scale models

to reproduce real process

conditions

• Apply CFD models to

evaluate & optimize

product

• Awarded 120+ patents for

advancing technologies

• Employing 70+ professional

in the lab



Reduce Cost of Electricity

• Lower power consumption by

sulphite sensor control

• Lower lime consumption using

unique egg-crate nozzles &

Performance Enhancement Plate

Wet FGD – Open Spray Tower (OST)

The best just got better: Alstom latest 3rd generation WFGD-OST

Lower Environmental Footprint

• > 99% SO2 removal

• Up to 6.0% Sulphur in coal

Increase Flexibility & Reliability

• Largest fuel flexibility, including

various types of coals and oil

• Can successfully and economically

follow all boiler load changes

• 40+ years of

continuous innovation,

with latest 3rd

Generation WFGD-

OST

• 60+ GW installed in

Power

• Up to 1,300 MW unit

size

• Highly efficient

absorber design with

less spraying banks

and power & reagent

consumption



• Unique turbulent bed

reactor design with no

spraying nozzles,

piping and pumps

• Up to 360 MW unit

size in operation

• Superb SO2, PM and

SO3 removal

• Compact design and

low power

consumption

• Lower maintenance

requirement due to

design with less

moving parts

FlowpacTM Absorber

Highly Efficient and Compact WFGD


• Lower power consumption by air lift

“triple duty” agitation, pumping and

oxidation

• Lower lime consumption using

intimate turbulent bed absorption



• High PM and SO3 removal

• Small footprint


• Excellent performance, even for

high sulphur fuel mixtures incl.

HFO

• High reliability by minimizing

moving parts



• Pioneer in SWFGD

with 1st installation in

1968

• 50+ GW in Power

alone

• Proven experience

with 1,000 MW unit

• Unique packed tower

design

• No reagent and no by-

product, with superior

restoration quality of

discharged seawater

Seawater Flue Gas Desulphurisation – (SWFGD)

NO.1 in SWFGD with ~60% of installed base globally


• Lower power consumption resulting

from packed tower design

• No additional cost for reagent and

end-product disposal

• Lower maintenance cost


• > 98% SO2 removal demonstrated

• Up to 4.5% Sulphur in Heavy Fuel

Oil (HFO)



coal, HFO and industrial flue gas

• Robust design without nozzles,

leading to high reliability



• 20+ years of

successful commercial

operation

• 15+ GW installed for

Power

• Compact footprint:

<50% footprint

compared to SDA

• Modular scalable

design

• Water, flyash, reagent

are blended outside

the flue gas stream.

• Low construction costs


• Lower lime consumption with

optimized hydrator/mixer design

• Local Construction

• Zero Liquid Discharge, low water

consumption

Dry FGD NID™

Alstom patented technology, No.1 in Dry FGD globally



• Up to 4% Sulphur in coal

• Multi-pollutant control: SO2,

SO3,HCL, HF, PM, Hg (with ACI)



heavy fuel oils and petcoke

• Suitable for PC and CFB boilers

• Can successfully and economically

follow all boiler load swings



• 60+ years of

experience

• 15+ GW installed

capacity for power and

industry worldwide

• Alstom patented rotary

atomizer technology

• Dual fluid nozzle

design is also

available for industrial

applications


• Lower lime consumption by

patented atomizer technology

• Zero Liquid Discharge, low water

consumption

Dry FGD Spray Dryer Absorber – (SDA)

Alstom proprietary Flex Shaft Atomizer (FSA) solution



• Up to 2.5% Sulphur in coal

• Multi-pollutant control: SO2,

SO3,HCL, HF, PM, Hg (with ACI)


• Multiple atomizers per reactor

• Online maintenance (2 atomizers

running, one down)



• 30+ years of

experience

• 46+ GW installation

• 80+ successful

installations worldwide

• Catalyst expertise

through partnerships

with leading catalyst

suppliers

• EPC capabilities with

design tailored to

existing site conditions

and optimized outage

time


• Ammonia injection grid allows very

precise ammonia dosage to ensure

optimal system efficiency and

performance.

• ADIS for aqueous ammonia

Selective Catalytic Reduction – (SCR)

Large portfolio of configurations with high NOx removal efficiency


• Up to 95% NOx removal

• < 2ppm ammonia slip

• New IsoSwirl™ mixing technology

improves flue gas-ammonia

contact for better performance


• Large portfolio with high dust, low

dust and tail-end configurations to

adapt to the most stringent plant

conditions and environmental

legislations



• 233+ GW installed in

power generation

• Effective Cleaning

System design with

robust tumbling

hammer

• Best-in-Class

Integrated ESP

Control systems: 3rd

Generation Intelligent

Controller (EPIC III)

• Switch Integrated

Rectifiers (SIR) for

increasing power input

into ESPs

Electrostatic Precipitators – (ESP)

Largest reference base on a variety of fuels


• Lower capital cost through more

compact sizing

• Lower power consumption by

minimum 5% thanks to best-in-

class controllers


• > 99.95% removal efficiency

• <10 mg/Nm3 emissions



heavy fuel oils

• Constant efficiency for varying

boiler load conditions



Fabric Filters – (FF)

Consistent lower compliant costs for dynamic process requirements

• 46+ GW (standalone)

installed in Power

• Up to 12m tall filters

for reduced footprint &

operational costs

• Renowned Optipulse®

filtration technology

with gravimetric flow &

Optipow® plunger

valves for efficient bag

cleaning

• Standalone

applications or

integrated at the down

stream of SDA, NIDTM,

AbartTM, Mer-CureTM,

FilsorptionTM


• Lower Capital Cost with tall bag

designs of up to 12 m

• Lower auxiliary consumption like

compressed air


• > 99.97% removal efficiency

• High PM10 & PM 2.5 removal

efficiency

• < 5 mg/Nm3 emissions


• Largest fuel flexibility and ability to

handle varying boiler loads

• Bag life of 5+ years achieved



• Mer-CureTM

Sorbent injection at

high temperatures for

faster oxidation

Uniform de-

agglomerating, particle

size reduction and

distribution of the

sorbent

Designed for use with

3rd party sorbents to

provide customer with

maximum flexibility

• FilsorptionTM

PAC* injection process

Upstream of AQCS

equipment

* Powdered Activated Carbon

Mercury Control

Achieve high removal efficiencies at drastically reduced sorbent consumption rates


• Mer-CureTM consumes less than

50% of sorbent than conventional

PAC


• > 90% removal efficiency


• Flexibility in injection points and

downstream PM equipment



Pollutant Alstom Process References Removal Performance

NOx Selective Catalytic Reduction 46GW >95%

SOx

Open Spray Tower 60GW >99%

FlowpacTM Absorber 1GW >99%

Dry Flue Gas Desulphurisation 30GW >98%

Seawater Desulphurisation 50GW >98%

Particulates

Dry Electrostatic Precipitators 233GW <10mg/Nm3

Wet Electrostatic Precipitators 2GW <10mg/Nm3

Fabric Filters (standalone) 46GW <5mg/Nm3

SOx/HCI/HF/Hg NID & Spray Dryer Absorber 136 installations ≥98% for SO2

Mercury Mer-CureTM /FilsorptionTM 8GW >90%

NOX: Nitrogen Oxides SOX: Sulphur Oxides HF: Hydrogen Fluoride HCl: Hydrogen Chloride Hg: Mercury

ECS Performance in Power

Alstom ECS is a world leading supplier of AQCS



Key References

Largest References Worldwide

Spurlock 1, 2, 3 & 4

USA

Almost all back-end

equipment supplied by Alstom

SCR + WESP +

WFGD on #1 & 2

NID on #3 & 4, DESP on #1

Shoaiba

Saudi Arabia

All Alstom plant with high

Sulfur HFO

SWFGD + ESP

Cliffside

USA

Alstom patented ZLD

process, achieving

extremely low emissions

SDA + FF + WFGD

Sines 1, 2, 3 & 4

Portugal

Alstom DeNOx systems in a

plant with very high

operation temperature

(425C)

SCR

Indian River 4

USA

Latest NID design supplied

to large utility boiler with

440MW unit size

NID Dry FGD

EMAL

UAE

ABART GTCs & Anode Bake

FTCs with SWFGD and

ALFEED Alumina Feeding

System on World’s No.1

Single Site Aluminium

Smelter 1.25MT/Y

BUV/ Malmberget

Sweden

The largest pelletizing plant,

achieving extremely low

emissions in PM, SO2, Hcl

and HF

ESP + Dry FGD with FF

Manjung 1, 2, 3 & 4

Malaysia

AQCS for South-East Asia’s

first & largest supercritical

power plant

SWFGD + ESP on #1,2,3

SWFGD + FF on #4

Filborna

Sweden

AQCS for Europe most

modern Waste-to-Energy

facility

NID + Condenser

Megalopolis

Greece

Successful design for high

Sulphur coal with flue gas

flow of 16,500mg/Nm3, dry,

6% O2

WFGD



Market overview CO2 Capture technologies

Source: Vattenfall

Pre-combustion (New only)

Pre-combustion

• Pre-combustion (Integrated Gasification Combined Cycle - IGCC) is based on gasification which converts a fossil fuel into synthesis gas composed of CO and hydrogen. Following shift conversion (CO+H2O -> CO2+H2), the resulting H2

product is burned in a gas turbine.

Post-combustion Oxy-combustion (New + retrofit) (New + retrofit)

Oxy-combustion

• Fuel is burned in a mixture of oxygen and re-circulated flue gas. Due to the absence of Nitrogen, the resulting flue gas is rich in CO2.

• After water condensing and further purification, CO2 is compressed and sent for storage or re-use.

Post-combustion

• Chemical absorption of CO2 (advanced amines and chilled ammonia).

• Flue gas is contacted with a chemical solvent which reacts with the CO2 or is captured by physical process. Raising the temperatures reverses the above reaction – releasing CO2 and allowing the solvent to be recycled



CCS is happening

Completed TESTS COMPLETE

AEP Mountaineer USA – 58 MWth Chilled Ammonia, Coal

EoN Karlshamn Sweden - 5 MWth Chilled Ammonia, Fuel

WE - Energie USA WI - 5 MWth Chilled Ammonia, Coal

DOW Chemical Co. USA, WV Adv. Amines - Coal

OPERATING Vattenfall Schwarze Pumpe, Germany 30 MWth, Oxy - Lignite

Total Lacq France - 30 MWth Oxy - Gas

Alstom BSF Windsor US - 15 MWth Oxy - Coals

2nd Gen

DOE/Alstom Windsor US - 3 MWth Chemical Looping, Coal

Alstom Labs Växjö Sweden – 0.25 MWth Post C.-multi purpose

RFCS EU - Darmstadt Germany - 1 MWth Chemical Looping - Coal

2nd Gen

TCM Mongstad Norway 40 MWth, Chilled Ammonia, CHP & Refinery Offgas (RCC)

Alstom GPU Pilot (Mobile) 0.3 MWth

OPERATING

LARGE-SCALE PROJECTS (under development)

White Rose CCS Project UK - 426 MWe Oxy Hardcoal

Alstom – title of the presentation - P 21

EDF Le Havre France - 5 MWth Adv. Adv. Amines - Coal



• Preferred Bidder in the UK’s £1Billion CCS Commercialisation Programme

• FEED Contract awarded - signed by the UK Government on 20th December 2013

• FEED underway: detailed risk reduction and planning programme leading to financial close, FID and construction commencement.

• Continuing work with the UK Government (DECC) towards Project Contract and Contract for Difference (CfD)

• NER 300 Award Decision: On 8 July 2014, White Rose project secured award decision on funding up to €300M, sponsored by UK Government; only CCS project in the NER competition

• Engaging with funding community after strong interest shown during the pre-FEED phase

• White Rose on track for a Final Investment Decision end 2015

White Rose Project: January 2014

Oxy-Power

Plant

CO2 Transport &

Storage

Location: Drax Power Station, North Yorkshire, UK

PROJECT DEVELOPERS:

Alstom Drax BOC-Linde

National Grid &



Partnerships and references

Alstom collaborates with multiple international companies

to realise the scale-up of CO2 Capture and Storage



Capture-Ready study

Identified pre-investments for future capture retrofit - Coal

Alstom Capture Ready solutions developed upon three pillars:

Early and substantial investment in Capture technologies development

Integrated power plant expertise (EPC supplier of turnkey power plant)

Component supplier experience (major equipment in 25% of the world installed base)

Partnership with Schlumberger to cover the entire CCS chain

Provisions in arrangement planning

Steam Turbine: reservations in turbine design for future

steam extraction

Electrical & Control Building:

Extra space

Transformer Area: installing an isolated bus

Stack duct: potential longer

stack duct

Waste Water Treatment System: foresee interconnection with power block WWTS

FGD: leaving space for upgrade

Optimisation of the Boiler heat transfer surfaces

according Modifications of heat load sharing

Optimisation of the cooling system recovery of heat in CO2 capture and

compression

www.alstom.com

With Alstom, preserve the environment.

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