“steinmüller-tagung” 2013 23. – 24. april 2013

1Revamp and Retrofit of FGD Plants

“Steinmüller-Tagung” 2013 23. – 24. April 2013

Gummersbach, Germany

Titel / title:

Vortragender / presenter:

Revamp and Retrofit of FGD Plants

Dr. S. Binkowski

2Revamp and Retrofit of FGD Plants

Employment Record Dr.-Ing. Stefan Binkowski

since 02/13

Steinmüller Engineering GmbH, Gummersbach, Germany Department Manager Flue Gas Cleaning Process

2009- 2013

Steinmüller Engineering GmbH, Gummersbach, Germany Head of Flue Gas Desulphurization Department

2005- 2009

Steinmüller Engineering GmbH, Gummersbach, Germany Process Engineer Flue Gas Cleaning

2001- 2005

Lehrstuhl Umwelttechnik, Fachbereich Chemietechnik, Universität Dortmund, Germany, Dr.-Ing. (PhD)

2001 Graduation - Universität of Dortmund, Germany,Dipl.-Ing. (M.Sc. Chemical Engineering)

3Revamp and Retrofit of FGD Plants

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 RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)

4Revamp and Retrofit of FGD Plants

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 RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)

5Revamp and Retrofit of FGD Plants

Medupi 6 x 800 MW FGD Concept and Basic Engineering

Tutuka 6 x 600 MW

6Revamp and Retrofit of FGD Plants

Medupi 6 x 800 MW FGD Concept and Basic Engineering

7Revamp and Retrofit of FGD Plants

Medupi 6 x 800 MW FGD Concept and Basic Engineering

One of the largest FGD systems in the world,

2nd

in South Africa

8Revamp and Retrofit of FGD Plants

Medupi 6 x 800 MW FGD Concept and Basic Engineering

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•

…

Eskom

9Revamp and Retrofit of FGD Plants

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 RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)

10Revamp and Retrofit of FGD Plants

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

11Revamp and Retrofit of FGD Plants

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 RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)

1212

FGD Engineering/Optimization – NUON Hemweg 8

680 MWbuilt by ESTS / HTS in 1994revamp by Steinmüller Engineering 2007scrubber diameter ~18 m

13Revamp and Retrofit of FGD Plants

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

FGD Engineering/Optimization – NUON Hemweg 8

14Revamp and Retrofit of FGD Plants

Optimizing gas flow distribution – ANP Advanced Nozzle Positioning

New, optimized spray banks

Better flowdistribution

15Revamp and Retrofit of FGD Plants

•

Effective use of secondary dispersion to increase surface for absorption and overall removal efficiency

Bright color of spray due to refraction indicates small droplets

Upper opening of tangential nozzle

Optimizing gas flow distribution – ANP Advanced Nozzle Positioning

16Revamp and Retrofit of FGD Plants

71 %

7.2 % Emission

92.8 % SO2 Removal

0

10

20

30

40

50

60

70

80

90

100

Effic

ienc

y [%

]Su

mp

Leve

l [m

]

0

100

200

300

400

500

600

700

800

Con

cent

ratio

n [p

pmv]

Load

[MW

]

Removal Efficiency [%]Sump Level [m]SO2 Inlet [ppm]SO2 Outlet [ppm]Total Load [MW]

89,84 %

22

0

10

20

30

40

50

60

70

80

90

100

Effic

ienc

y [%

]Su

mp

Leve

l [m

]

0

100

200

300

400

500

600

700

800

Con

cent

ratio

n [p

pmv]

Load

[MW

]

Removal Efficiency [%]Sump Level [m]SO2 Inlet [ppm]SO2 Outlet [ppm]Netto Load [MW]

92,78 %

22

Achieved efficiency improvement (3 of 4 levels in operation)

89.8 % SO2 Removal

10.2 % Emission

Increasing the FGD removal efficiency by 2.9 % points means reducing the SO2

emissions by nearly 30 %

71 %

29 %

17Revamp and Retrofit of FGD Plants

≈

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 SO2

cap

Efficiency vs. L/G

0

20

40

60

80

100

0 50.000L/G

80

85

90

95

100

20.000

+ 18.2 %

+ 2.9 %

Achieved efficiency improvement (3 levels)

2.9 % of increased efficiency by spray bank layout equals an L/G increase of 18.2 % (~380 kW) !

18Revamp and Retrofit of FGD Plants

• 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

Optimizing gas flow distribution – Potential of wall ring installation

19Revamp and Retrofit of FGD Plants

Increasing sump level will increase total L/G Removal efficiency increased by 2.1 %-points

Optimizing FGD operation – Absorber liquid level vs. Number of pumps

20Revamp and Retrofit of FGD Plants

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 RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)

21Revamp and Retrofit of FGD Plants

Dual Flow Tray Tower

Perforated Plate EndsBent Up For Bolted

Connections

Perforated PlatesEquidistant Hole

Center Lines

Dual Flow Tray

Design

SESS WFGD Technology - Dual Flow Tray Absorber

22Revamp and Retrofit of FGD Plants

Acid Gas Control - WFGD

• Maximize mass transfer (e.g. SO3

, dust)• Shorter absorber design• 15 -

20 % lower Liquid/Gas ratio• Access/Maintenance support grid

Dual Flow Trays

• Lower outlet emissions possible•

Scale-free operation at IPL Petersburg w/multiple trays since 1983

23Revamp and Retrofit of FGD Plants

Owensboro Municipal Utilities - Elmer Smith Station Units 1 & 2

Owensboro Municipal UtilitiesElmer Smith Generating StationUnits 1 and 2Owensboro, Kentucky

• Wet FGD System 1994 Startup

• Open Spray Tower Absorbers

• 2007 Upgrade w/ Dual Flow Trays

• HaRDE®

Precipitators

• 151 MW / 290 MW

24Revamp and Retrofit of FGD Plants

Owensboro Municipal Utilities - Elmer Smith Station Units 1 & 2

Open Tower

DFT Tower

Startup

1995

Retrofit 2007Number of Trays

None

OneGas Flow (Am3/h)

3,167,375

3,167,375Inlet SO2

(ppmv)

2,000

2,000Outlet SO2

(ppmv)

80

40SO2

Removal

96 %

> 98 %Pressure Drop Increase (mbar)

< 5

No other changes to operating system components or chemistry

25Revamp and Retrofit of FGD Plants

•

Flue gas desulphurisation system for unit no. 4 of 150 MWel and hot water boiler of 103,2 Gcal/h

Paroseni Absorber Retrofit

26Revamp and Retrofit of FGD Plants

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 RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)

27Revamp and Retrofit of FGD Plants

Paroseni Absorber Retrofit – Design Parameter

•

Flue gas desulphurisation system for unit no. 4 of 150 MWel and Hot Water Boiler of 103,2 Gcal/h

28Revamp and Retrofit of FGD Plants

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

29Revamp and Retrofit of FGD Plants

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 RetrofitAbsorber Process Engineering and Main Components (LAB/CNIM)

30Revamp and Retrofit of FGD Plants

Steinmüller Engineering provides

•

experienced consulting

•

proven optimization concepts

•

customized engineering solutions

for your FGD.

Thank you!