Wet FGD System

Overview and Operation

Ray Gansley

WPCA Wet FGD Seminar

Power Gen International
December 1, 2008
 Agenda

Introduction

Major Process Equipment

Balance of Plant Equipment

Controls

Summary

WPCA Wet FGD Seminar - December 1, 2008

 Process Flow Diagram

STACK ABSORBER
WATER
SPRAY TOWER
ABSORBER

ELECTROSTATIC MAKE-UP
PRECIPITATOR TO BALL WATER
MILL TANK

CHLORIDE
PURGE

LIMESTONE

HYDROCLONE

AIR BELT FILTER

GYPSUM
DEWATERING
FROM MW
TANK
REAGENT
BALL MILL
PREPARATION

WPCA Wet FGD Seminar - December 1, 2008

 Agenda

Introduction

Major Process Equipment

Balance of Plant Equipment

Controls

Summary

WPCA Wet FGD Seminar - December 1, 2008

 Absorber Island

Absorber

Spray Switchgear
Pumps

Oxidation
Compressors

WPCA Wet FGD Seminar - December 1, 2008

 Absorber Designs

Open Spray Tower Fountain Tower

Tray Tower Jet Bubbling Reactor

WPCA Wet FGD Seminar - December 1, 2008
 Absorber Unit Operations
Unit Operations
Inlet gas distribution,
humidification
Spray zone gas/liquid contact
Mist eliminator zone
liquid/gas separation
Reaction tank oxidation,
dissolution, crystallization
Design Goals
Lowest lifecycle cost
Capital
O&M
High reliability

WPCA Wet FGD Seminar - December 1, 2008

 Absorber Inlet

Highly corrosive
environment
SO3 condensation
Deposits/splash-back
Design/construction
Solid 3/16 thick C-276
10 slope toward absorber
Extends 10-15 ft. from shell
Internal overhead deflector
and side shields
Test ports and emergency
quench nozzles
Gas velocity 3,000-3,600
ft/min

WPCA Wet FGD Seminar - December 1, 2008

 Absorber Shell

Flared-Side Straight-Side

WPCA Wet FGD Seminar - December 1, 2008

 Contact Zone

Multiple spray levels with

dedicated pumps allows
efficient turndown
Gas velocity 13-14 ft/sec

Spray flow
Typical afternoon
thunderstorm 1-2 in/hr
Spray tower 10 ft/min

WPCA Wet FGD Seminar - December 1, 2008

 Contact Zone

Design Approach
Intimate gas/liquid contact
No gas sneakage
Multiple spray stages depending
on SO2 inlet and removal
efficiency
Overall spray coverage (>200% at
3-feet) and nozzle distribution to
provide even distribution and
prevent gas sneakage.
Wall rings to prevent gas
sneakage near side walls.
Pressure drop vs. pumping power
trade-off

WPCA Wet FGD Seminar - December 1, 2008

 Spray Nozzles

Multiple counter-current spray

stages
Nozzle type
Top stagesingle orifice hollow
cone
Lower stagesdual orifice
hollow cone
Sauter mean droplet diameter of
~2,000 micron at 8 psig
Silicon carbide construction

WPCA Wet FGD Seminar - December 1, 2008

 Mist Eliminator

Mist Eliminator

Spray Zone

z Two stages of vertical-flow

chevron vanes
z Construction
Polypropylene
Polysulfone
FRP
Alloy/stainless steel
WPCA Wet FGD Seminar - December 1, 2008
 Mist Eliminator Operation

Carryover
5 10 15 20 25
Gas Velocity (ft/sec)
Gas Flow

WPCA Wet FGD Seminar - December 1, 2008

 Mist Eliminator Wash System

Fresh water wash on

intermittent basis
First stage washed from
below (1.5 gpm/ft2) and above
(0.75 gpm/ft2)
Second stage washed from
below (0.75 gpm/ft2)
Construction
Piping FRP, polypropylene,
alloy/SS
Nozzles polypropylene,
alloy/SS

WPCA Wet FGD Seminar - December 1, 2008

 Absorber Recycle Pumps

y Typical size: 50,000-

75,000 gpm at 55-85 TDH
y Pump Efficiency: 87-90+%
y 1,000-2,500 hp
y Horizontal, centrifugal
y Rubber lined casing
y Impeller
Hard metal
Rubber-covered

WPCA Wet FGD Seminar - December 1, 2008

 Spray Pump Capacity

70,000

60,000

50,000

40,000
Flow (gpm)

30,000

20,000

10,000

1970 1980 1990 2000

WPCA Wet FGD Seminar - December 1, 2008

 Recycle Pump Curve

WPCA Wet FGD Seminar - December 1, 2008

 Reaction Tank
Integral to absorber
Functions
Limestone dissolution
Oxidation
Gypsum crystallization
Design considerations
Solids and liquid residence time
Foaming/freeboard
Side entry agitators with air lances

WPCA Wet FGD Seminar - December 1, 2008

 Materials of Construction

Shell Mist Eliminators

z Rubber-lined carbon z FRP
steel
z Polypropylene
z Flakeglass-lined carbon
z Polysulfone
steel
z SS/alloy
z Stainless steel
(317LMN)
z Duplex stainless steel Headers
(2205, 255) z Rubber-lined carbon steel
z Nickel-based alloy z FRP
z Roll-clad alloy z Stainless steel (317LMN)
z Lined concrete (tile, z Duplex stainless steel
polypropylene) (2205, 255)
z Nickel-based alloy
External Spray Piping
z FRP
Inlet
z Rubber-lined carbon
steel z C-276
z SS/alloy

WPCA Wet FGD Seminar - December 1, 2008

 Reagent Preparation Island

Day Bin

Classifier

Ball Mill
Feed
Tank

WPCA Wet FGD Seminar - December 1, 2008

 Limestone Grinding System

REAGENT
SILO
CLASSIFIER
TO
ABSORBER

FROM MW TANK

BALL MILL

REAGENT
BALL MILL
FEED
RECYCLE
TANK
TANK

WPCA Wet FGD Seminar - December 1, 2008

 Limestone Preparation

Limestone grinding
Horizontal/vertical
wet ball mills
On-site vs. off-site
preparation
Product ground to
90-95% < 44 ; 30% solids
Rubber-lined with
hardened steel balls

WPCA Wet FGD Seminar - December 1, 2008

 Pre-Ground Limestone Injection

Dry, pre-ground limestone feed options

Pneumatic injection into reaction tank below slurry level
Pre-slurry in small tank
Advantages
Low capital cost (i.e. no ball mills, auxiliary equipment,
buildings, etc.)
Less equipment to maintain
Disadvantages
Higher delivered cost
Lifecycle cost evaluation on case-by-case basis

WPCA Wet FGD Seminar - December 1, 2008

 Dewatering Island

Hydroclone

Belt Filter

Vacuum
Pump
WPCA Wet FGD Seminar - December 1, 2008
 Primary Dewatering
Initial solid/liquid separation
step
Feed: 15-20% TSS
Underflow: 50-55% TSS
Overflow: 3-5% TSS
Overflow enriched with
CaCO3 due to particle size
difference; improved reagent
utilization
Steel casing with rubber,
urethane, and ceramic
internals

WPCA Wet FGD Seminar - December 1, 2008

 Secondary Dewatering

Horizontal belt filter

8-10% moisture in gypsum
Optimal for cake washing
Rotary drum filter
10-15% moisture
Smaller footprint
Other options
Gypsum stacking
Centrifuge
Thickener

WPCA Wet FGD Seminar - December 1, 2008

 Wallboard Gypsum

Typical specification:
>95% CaSO42H2O
<0.51.0% CaSO3H2O
<100 ppm Cl
<10% moisture
pH 68
3040 MMD
Requires:
High purity limestone (95
96%)
High efficiency ESP/FF
99+% oxidation
Belt filter
Cake washing

WPCA Wet FGD Seminar - December 1, 2008

 Agenda

Introduction

Major Process Equipment

Balance of Plant Equipment

Controls

Summary

WPCA Wet FGD Seminar - December 1, 2008

 Limestone Delivery/Storage

Truck, rail, or barge

delivery
x 0 (20 x 0 mm)
crushed limestone
Outdoor long-term
storage feasible in most
areas
Indoor/covered storage
in harsh/wet climates

WPCA Wet FGD Seminar - December 1, 2008

 Limestone Silo

Provide buffer between limestone pile

and ball mill operation
16-24 hr capacity
Carbon steel construction with
polymer or stainless steel hopper
lining
Vibrating bottom/mechanical
activation
Vent filter for fugitive dust control

WPCA Wet FGD Seminar - December 1, 2008

 Gypsum Storage/Handling

Covered storage options

Direct discharge to bunker/
manual reclaim
Convey to dome/manual
reclaim
Convey to building or silo/
automated reclaim
Open pile
Feasible
Possible issues: moisture,
fugitive dust, leaching
Selection depends on:
On-site storage requirement
Gypsum contract

WPCA Wet FGD Seminar - December 1, 2008

 Fan Arrangement Retrofit

STACK

ELECTROSTATIC
PRECIPITATOR

ID FAN

WPCA Wet FGD Seminar - December 1, 2008

 Fan Arrangement Retrofit

STACK

ABSORBER

ELECTROSTATIC
PRECIPITATOR

ID FAN

WPCA Wet FGD Seminar - December 1, 2008

 Fan Arrangement Retrofit

STACK

ABSORBER

ELECTROSTATIC
PRECIPITATOR

BOOSTER
ID FAN
FAN

WPCA Wet FGD Seminar - December 1, 2008

 Fan Arrangement Retrofit

STACK

ABSORBER

ELECTROSTATIC
PRECIPITATOR BOOSTER
FAN

ID FAN

WPCA Wet FGD Seminar - December 1, 2008

 Wastewater Treatment
Purge stream required to control
chlorides/inert solid for wallboard
gypsum
Purge stream treatment strategy is
site-specific; depends on:
Discharge limits
Receiving body
FGD process design
Fuel, limestone, make-up water
Treatment options:
Direct discharge
Volume reduction (evaporation,)
Physical/chemical treatment
Suspended solids
pH adjustment
Heavy metals removal
COD removal
WPCA Wet FGD Seminar - December 1, 2008
 Agenda

Introduction

Major Process Equipment

Balance of Plant Equipment

Controls

Summary

WPCA Wet FGD Seminar - December 1, 2008

 WFGD Controls

Distributed Control Systems

Overview
Redundancy
Primary WFGD Control Loops
& Instrumentation
Absorber Area
Flue Gas System

WPCA Wet FGD Seminar - December 1, 2008

 WFGD Control Systems
z Distributed Control Systems (DCS)
Control and automation of WFGD
processes and components
Interface with remaining power
plant controls
Monitor key process parameters
Process trends, reports, historical
data logging
z Local Control Panels (LCP)
z Programmable Logic Controllers
(PLC)
z Main FGD Control Area
Dedicated WFGD Control Station
Centralized WFGD Control with
Boiler/Power Plant

WPCA Wet FGD Seminar - December 1, 2008

 Distributed Control System
DCS CONFIGURATION DIAGRAM

Operator Operator Engineering

Station Station Station
Line Printer Line Printer Laser Printer

Redundant Data Highway

Serial Serial Serial Serial

Redundant Device Device Redundant Device Device Redundant
Process Process Process
Controller Controller Controller

Local Local Local

I/O I/O I/O

Remote Remote
I/O I/O

WPCA Wet FGD Seminar - December 1, 2008

 Major Control Loops - Absorber

pH L

Make-Up
Reagent Water
Feed D

Solids /
Gypsum
Bleed
WPCA Wet FGD Seminar - December 1, 2008
 pH / Reagent Feed Control

z Scrubbing Liquor pH
Most important process variable
to be controlled in WFGD
continuous, in-line monitoring,
daily lab verification
Indication of the amount of
CaCO3 in scrubbing solution 0 7 14
acid Neutral base
Scrubbing liquor below desired
range lower SO2 removal H2O
efficiency
Scrubber liquor above desired 5.3 5.8
range higher SO2 removal Scrubbing
efficiency, excess CaCO3 and Liquor pH
reduced gypsum byproduct purity

WPCA Wet FGD Seminar - December 1, 2008

 pH / Reagent Feed Control

LS Flow Controller

Absorber

FE Limestone
slurry

Reaction Tank

SO2 Boiler Load

(MW)

pH

pH

pH Controller

WPCA Wet FGD Seminar - December 1, 2008

 pH Instrumentation

LOCAL
DISPLAY
PANELS

TRANSMITTERS

pH PROBES

PROCESS
PIPING

WPCA Wet FGD Seminar - December 1, 2008

 Gypsum Bleed / Solids Control

Flue Gas
z Scrubber Slurry Solids Water Vapor
Important WFGD process
variable, verified daily with
laboratory samples Mist
Eliminator
Scrubber slurry solids: gypsum, Wash Water
Dewatering
limestone, flyash, inerts Return
Flue Gas Make-up
Numerous inputs affecting water Water Vapor Water
balance and solids concentration
Control solids concentration Limestone Slurry
Absorber
within narrow range: 14-16 wt.% Oxidation Air Bleed Stream
z Solids Control Sat. Water

Solids too low: potential for

gypsum scaling
Solids too high: increased
potential for wear of equipment
Equipment sizing

WPCA Wet FGD Seminar - December 1, 2008

 Gypsum Solids / Density Control

Return to
Absorber

Absorber

Primary
Dewatering
Hydroclones
Reaction Tank
L

L Secondary
LEVEL Dewatering

DE

DENSITY

ABSORBER BLEED
PUMPS
WPCA Wet FGD Seminar - December 1, 2008
 Density Measurement
Nuclear Density Meters
Source emits gamma
radiation through process
Detector measures energy
of radiation
Capable of detecting
process variations within
desired narrow range
Safe Nuclear Density Meter
Accurate
Simple calibration
Verify with laboratory
analyses

WPCA Wet FGD Seminar - December 1, 2008

 Density Instrumentation

PROCESS
SLURRY LOCAL
DISPLAY
PANEL

DENSITY
METER

WPCA Wet FGD Seminar - December 1, 2008

 Level / Make-Up Water Control

Level Controller

Absorber

Make-up water

Reaction Tank
L f(x)
OX AIR

L f(x)

DE DY

DENSITY

WPCA Wet FGD Seminar - December 1, 2008

 Booster Fan Control

NEW STACK

EXISTING
STACK
F
STACK REVERSE FLOW ID Fan Load,
Boiler MW
DUCT PRESSURE
ZY

VANE PITCH
CONTROL

SPRAY TOWER
ABSORBER

BOOSTER FANS
ID FANS

WPCA Wet FGD Seminar - December 1, 2008

 Booster Fan Control

SO2
TREATED FLUE
GAS

EXISTING
STACK

UNTREATED
FLUE GAS ID FAN LOAD,
(BYPASS) BOILER (MW)

ZY
DUCT
PRESSURE VANE PITCH
CONTROL
ID FANS P

SPRAY TOWER
ABSORBER

BOOSTER FANS

ID FANS
WPCA Wet FGD Seminar - December 1, 2008
 Emergency Quench
OUTLET (CLEAN)
FLUE GAS

TY QUENCH
WATER

INLET FLUE
GAS

SPRAY TOWER
ABSORBER
WPCA Wet FGD Seminar - December 1, 2008
 Agenda

Introduction

Major Process Equipment

Balance of Plant Equipment

Controls

Summary

WPCA Wet FGD Seminar - December 1, 2008

 WFGD Operations Staff

O&M staffing varies; depends on:

Owner staffing philosophy/
practices
Plant layout/design
Reagent/byproduct
Labor bargaining agreements
Other equipment at plant

WPCA Wet FGD Seminar - December 1, 2008

O&M Staff for 2 x 700 MW WFGD

Position Description No. Coverage

FGD Supervisor 1 1 shift, 5 days/week
FGD Operator 1 3 shifts, 7 days/week
FGD Mechanic 1 1 shift, 5 days/week
FGD Computer Tech 1 1 shift, 5days/week
FGD Specialist 1 1 shift, 5 days/week
FGD Material Handling 1 3 shifts, 7 days/week
 Lifecycle Cost Comparison

High Sulfur Low Sulfur

TotalPlantCapitalCost $ 150,000,000 120,000,000
$/kW 250 200
PlantCapacity (perunit) MW e 600 600
No.Units 1 1
PlantCapacity Factor % 85 85
EquivalentFull-Load Hour hr 7,446 7,446
Escalation Rate % 3.0 3.0
NPV DiscountRate % 10.0 10.0
SO2 Rem oval % 98 98
SO2 Production Rate lb/hr 45,000 12,000
lb/M M Btu 7.50 2.00
ID Fan Flue Gas Flow acfm 2,100,000 2,220,000

WPCA Wet FGD Seminar - December 1, 2008

 Lifecycle Cost Comparison

High Sulfur Low Sulfur

No.O&M Personnel/Shift 5 5
O&M LaborRate $/hr 50.00 50.00
AQCS Pow er kW 9,000 4,500
Fan Pow erConsum ption kW 2,464 1,628
TotalPow er kW 11,464 6,128
Pow erCost $/kW -hr 0.03 0.03
Lim estone Consum ption lb/hr 74,709 19,922
Lim estone Cost $/ton 20.00 20.00
Gypsum Production lb/hr 138,618 36,965
Gypsum Price $/ton (5.00) (5.00)
Repair/M aintenance % ofTPC 1.5 1.5

WPCA Wet FGD Seminar - December 1, 2008

 Lifecycle Cost Comparison

Technology High Sulfur Low Sulfur

O&M Labor $/yr 2,190,000 2,190,000
Auxiliary Pow er $/yr 2,560,776 1,368,838
Lim estone $/yr 5,562,823 1,483,420
W W TS Reagents $/yr 1,500,000 500,000
Gypsum $/yr (2,580,382) (688,102)
Repair/M aintenance $/yr 2,250,000 1,800,000
Total $/yr 11,483,218 6,654,156
$/M W -hr 2.57 1.49

TotalPlantCapitalCost $ 150,000,000 120,000,000

O&M Cost(25-YrNPV) $ 138,240,000 69,540,000
Lifecycle Cost $ 288,240,000 189,540,000

WPCA Wet FGD Seminar - December 1, 2008

 Summary

WFGD system design is mature;

operation is routine
Major process islands
Absorber
Reagent
Dewatering
Key balance of plant equipment
Flue gas handling
Material handling
Wastewater treatment
Electrical system

WPCA Wet FGD Seminar - December 1, 2008

WPCA Wet FGD Seminar - December 1, 2008
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