cost effective flue gas desulfurization for boilers < 300...

Cost effective flue gas desulfurization

for boilers < 300 MWfor boilers < 300 MW

SOx NOx – 201912–13 September 2019,Vivanta - Dwarka, New Delhi

Content

Cost effective flue gas desulfurization for boilers < 300 MW

1 Who we are, what we do

2 Our view of Indian FGD needs

3 LIFAC FGD

March 21, 2019 © Valmet | Cost effective flue gas desulfurization2

5 Bonus: low temperature NOx control combined with FGD

4 Case example of 210 MW coal fired unit FGD

About ValmetAbout Valmet

From cloth making to high-tech processes

Progress built on 220 years of industrial history

2015MetsoProcess Automation

Systemsto Valmet

1951Valmet

1968–1996Several M&As:1986 KMW

1987 Wärtsilä paper finishing machinery

1992 Tampella Papertech

1999Metso created through merger of Valmet and Rauma

Acquisitions2000 Beloit Technology

2006 Kvaerner Pulping Kvaerner Power

2009 Tamfelt

End of 2013Demerger to Valmet and Metso

1797 Tampereen Verkatehdas

1841 Götaverken

1856 Tampella

1858 Beloit

1860 KMW

1868 Sunds Defibrator

1942Rauma-Raahe


Key figures in 2018

Orders received by business lineOrders receivedEUR 3,722 million

Net sales EUR 3,325 million

Comparable EBITAEUR 257 million

35%

29%

20%

13%

14%

10%

Orders received by area


EUR 257 million

Comparable EBITA margin7.7%

Employees (on Dec 31, 2017)

12,528

9%27%

Services

Automation

Pulp and Energy

Paper

13%

43%

North America

South America

EMEA

China

Asia-Pacific

Over 100 service centers, 85 sales offices, 35 production units, 16 R&D centers

Strong, global presence is a good platform for growth

North America

1,202

• 17 service centers• 7 production units

• 8 sales offices

China

1,752


• 6 sales offices

Employees on December 31, 2018March 21, 2019 © Valmet | Cost effective flue gas desulfurization6

Asia-Pacific

761

• 12 service centers• 12 sales offices

EMEA

8,303

• 16 R&D centers• 63 service centers

• 21 production units• 54 sales offices

South America

510


• 5 sales offices

Valmet energy generation offering

Renewables to energy Multifuel to energy Industrial boilers


Biomass to energy

• Boiler plants

• Modular power plants

• Heat plants

• Gasification plants

Waste to energy

• Boiler plants

• Modular power plants

• Gasification plants

• Boiler plants

• Coal-fired boiler plants

• Repowering

• Process Gas Boiler plants

• O&G boiler plants

• Heat recovery boiler plants

Rebuilds & Conversions

Air pollution control

Automation

Facts about Valmet’s air emission control business

70

350Advanced process

control installations

170

150Scrubber and FGD

installations for

boilers


70Electrostatic

precipitator andfabric filter

installations

170NOx control

systems

110 Marine scrubbers

for 60 ships

� World class technology and know-how

� Over 45 years of experience in air emission

control

Valmet air emission control solutions

� Over 200 in-house air emission control experts

at your service


Complete emission control with heat and water recovery

Valmet flue gas cleaning technologies

Dry

NOx control

• Flue gas scrubber

• Wet DeNOx

• ESP

• Bag house filter

• DSI

• Primary methods

• SNCR

• SCR

• Wet DeNO

Wet


• Wet DeNOx

• FGD

• Heat and water recovery

• DSI

• LIFAC FGD

• Wet DeNOx

Our view of Indian FGD needs– focus on < 300 MW units – focus on < 300 MW units

New regulations on emissions

Date of installation

PM SO2 NOx Mercury (Hg)

Before 31-12- 2003 100 mg/Nm3 600 mg/Nm3 for < 500 MW200 mg/Nm3 for > = 500 MW

600 mg/Nm3 0.03 mg/Nm3

for > = 500 MW


200 mg/Nm for > = 500 MW for > = 500 MW

After 01-01-2003& Upto 31-12-2016

50 mg/Nm3 600 mg/Nm3 for < 500 MW200 mg/Nm3 for > = 500 MW

300 mg/Nm3 0.03 mg/Nm3

On or after01-01-2017

30 mg/Nm3 100 mg/Nm3 100 mg/Nm3 0.03 mg/Nm3

Focus on < 300 MW units

Boiler type CFBC BFB Pulverized coal

Fuel Petcoke Coal Petcoke Coal Domestic Import

Present emission level, 400* 6 000 100– 200* 700–3 000 2 000* 6 000 300–700* 700–1 700 700–1 700 700–3 000

Need of desulfurization

emission level, mg/Nm3

400* 6 000 100– 200* 700–3 000 2 000* 6 000 300–700* 700–1 700 700–1 700 700–3 000

Emission limitNew units installed since 2017 – 100 mg/Nm3

Older units – 600 mg/Nm3

SO2 removal% required

0–25 90–98 0–50 14–97 70–95 90–98 0–86 14–94 14–94 14–97


* with limestone injection to furnace

LIFAC FGDLIFAC FGD

Water injection

Activation

reactor

FurnaceLimestone

injection

(Limestone Injection into Furnace and Activation of unreacted lime)

� Inexpensive reagent (limestone)

� CAPEX less than half of wet FGD

� Small footprint

� Up to 90% SO2 removal

LIFAC

Air preheating Recycle

Electostatic

precipitator


Step-by-step investment

Flexible technology

SO2 removal after each step

Step 1.

Furnace injection

25

Step 2.

Activation and recycle

70

Step 3.

Slurry ash recycle

90


~ 25% ~ 70% ~ 90%

Flue gas desulphurization Inkoo Power Station, Finland

Inkoo Power Station 4 x 250 MWe

Finland

Main data

Boiler• Coal fired unit No. 4

• 250 MWe

Coal

• Lower heating value 24.5 MJ/kg

• Analysis (as received, weight %)

S 1.0

Cl 0.2


Cl 0.2

H2O 8.7

Ash 17.4

Flue gas desulphurization

• Limestone injection and humidification for 100%

of flue gas

• Two reactors

• Flue gas amount through one reactor 450 000 Nm³/h

• SO2 emission 230 mg/MJ

• SO2 reduction 70%

Commissioning 1988 and 1989

Flue gas desulphurization Shand Power Station Saskatchewan, Canada

Shand Power Station Saskatchewan, Canada

Main data

Boiler• Lignite fire unit

• 300 MWe

Coal

• Calorific heating value 14.2 MJ/kg


C 39.9 N2 0.6

H 2.4 H O 32.6


CoalH2 2.4 H2O 32.6

O2 9.8 Ash 17.3

S 0.5


• Limestone injection for 100% of flue gas

• Humidification for 50% of flue gas

• Flue gas amount through one reactor 600 000 Nm³/h

• SO2 emission after reactor 95 mg/MJ

Commissioning June 1992

Flue gas desulphurization Richmond Power&Light White Water Valley Power Station, Indiana, USA

Richmond Power&Light White Water Valley Power Station, Indiana, USA

Main data

Boiler• Coal fired unit No. 2

• 60 MWe

Coal

• Bituminous coal

• Lower heating value 26.1 MJ/kg



Coal• Analysis (as received, weight %)

C 60.1 N2 0.9

H2 4.4 S 2.3–2.9

O2 8.0 H2O 12.3


• Limestone injection and humidification for 100%

of flue gas

• Flue gas amount through the reactor 306 000 Nm³/h

• SO2 reduction 75%

Commissioning 1992

LIFAC flue gas desulphurization system Nanjing Xiaguan Power Plant, China

Nanjing Xiaguan Power PlantChina

Main data

Unit # 1 and #3

Steam amount 2 x 420 t/h

Electric power 2 x 125 MWe

Fuel Bituminous coal


Coal amount 63.7 t/h

Coal sulfur content 0.92%

LHV 20.4 MJ/kg

SO2 removal rate 75%

SO2 emission < 460 mg/m3n

Commissioning 1998–1999

LIFAC flue gas desulphurization system Qianqing power plant, China

Qianqing power plantChina

Main data

Unit # 1

Steam amount 420 t/h

Electric power 125 MWe



Coal amount 60 t/h

Coal sulfur content 0.9–1.2%

LHV 21.7 MJ/kg

SO2 removal rate >80%


Commissioning 1999

LIFAC flue gas desulphurization system Shandong Zhanhua power plant, China

Shandong Zhanhua power plant,China

Main data

Unit # 3 and # 4

Steam amount 2 x 480 t/h

Electric power 2 x 150 MWe



Coal amount 68.8 t/h

Coal sulfur content 0.44%

LHV 21.3 MJ/kg

SO2 removal rate 80–85%


Commissioning 2005

Summary

� Low CAPEX and OPEX

� Well proven dry FGD technology

� SO2 removal up to 90%

� Step-by-step investment possible

LIFAC dry FGD

� Works with existing ESP

� Operates with limestone

� Small footprint

Positive impact on environment and economy


Bonus:

Low temperature NO control Low temperature NOx control combined with FGD

Solution for meeting tighter NOx emission limit

Plant data

Boiler 60 MWfuel

Existing flue gas cleaning ESP, wet scrubber


Existing flue gas cleaning equipment

ESP, wet scrubber

Pre-BAT NOx emission limit value 400 mg/Nm3

BAT emission limit value max. 225 mg/Nm3

Can’t meet emission limit

Uncontrolled NOx emission

300

350

400

450

500

Initial NOx (mg/Nm3)


0

50

100

150

200

250

Time

Emission limit 225 mg/Nm3

Not always meeting emission limit

Optimized combustion and SNCR

300

350

400

450

500

NOx after Combustion manager and SNCR (mg/Nm3)



0

50

100

150

200

250

Time

Emission limit 225 mg/Nm3

On-demand use of oxidant – additional NOx as needed

Optimized NOx control

300

350

400

450

500

NOx after Combustion manager and SNCR (mg/Nm3)



0

50

100

150

200

250

Time

Oxidant consumption

Emission limit = emission 225 mg/Nm3

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Comparison of technologiesComparison of technologies

FGD technology alternatives – Valmet has the offering

Each technology has its merits

Dry sorbent injection (DSI) Wet FGDLIFAC(Limestone Injection into Furnace and Activation


Dry sorbent injection (DSI) Wet FGD(Limestone Injection into Furnace and Activation

of unreacted carbon)

� Low investment

� High operating cost

� Best suited for waste-to-energy

� Low investment

� Low operating cost

� Best suited for smaller coal or petcoke fired boilers

� High investment

� Best suited for larger coal fired

boilers

210 MWe unit burning domestic coal, SO2 limit 600 mg/Nm3, 60% SO2 reduction

Reagent cost comparison

Wet FGD LIFAC DSI

Reagent Limestone Limestone Sodium bicarbonate

Reagent price INR 2 300 2 300 30 000

Stoichiometry 1.03* 2 1.4

* ) Per removed SO2


Reagent t/h 1.4 4.5 3

Reagent cost INR/h 3 220 10 350 90 000

Annual equivalent full load operating hours

7 000 7 000 7 000

Annual reagent cost INR

22 540 000 72 450 000 630 000 000

General comparison

Wet FGD LIFAC DSI

Reagent cost

Capex

Footprint


Fly ash utilization

By-product (gypsum)

Soil pollution

Auxiliary power

consumption

Delivery time

� Over 45 years of experience in air emission control

� Global service network

� Net sales over 3 billion euro

� 12,000 people around the world

We take your performance forward

� 12,000 people around the world

� 250 people in India


cost effective flue gas desulfurization for boilers < 300...

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