Thermax - NTPC Presentation

NTPC Rihand Power Station
Wet Flue Gas Desulfurization - Process Overview

Presented by: Mike Hammer
Senior Process Engineer
Marsulex Environmental Technologies
Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

MET - Your Full Service AQC Solutions Provider
.
Brief History
1934: Buell Engineering Company Mechanical 2008: Minnkota and Sunbury Awards
Collectors
2009: ASFGD contract with ZAP Pulawy Poland, CFB-
1950 -1960s: Buell ESP & fabric filter product lines FGD (Dry) Technology licensed, awarded
added
2010: Awarded WFGD contract with PacifiCorp
1971: Envirotech acquired Buell
April 2010: Signed MOU with Thermax
1981: Envirotech’s Buell + Chemico FGD Divisions
acquired by General Electric and incorporated as June 2011: 100% ownership by BHEP
General Electric Environmental Services Inc (GEESI) 2012: Adds Particulate control, Buell APC, and SCR
1994: Pilot demonstration unit and development of products, Awarded Grand Island SDA system
the first commercial ASFGD started at Dakota 2014: ASFGD contract with ZAP Police Poland, First
Gasification Company Stack Reheat System on large coal generating station
1997: GEESI acquired by Marsulex 2016: Awarded New AS-FGD contract within an
2001: Divested particulate, mechanical and industrial US Market - Sanders Lead
aftermarket 2019: Developed and awarded contract for
2001: Began licensing in China - total of 7 licensees Ammonium Sulfate process for Lead Paste recovery
in Lead Acid Battery Recycling system
2002: Began first WFGD project in China
2019: Kraft Powercon purchases MET, Thermax
2006: Awarded LCRA project awarded first MET Licensed WFGD Contract in India
2007: Syncrude UE-1 commercial acceptance
.
Overview of Business – Summary of Services
Installed Base
Traditional Ammonium Sulfate FGD Upgrades Selective

FGD Particulate
Flue Gas & Catalytic
Technology Control
Desulphurization Associated Services Reduction
26,000 MW
105,210 MW 2,250 MW 4,195 MW* 75,000+ MW
(4,000 USA)
• Wet and Dry FGD • Proprietary and patented • Performance upgrades • Electrostatic • Offer Selective
solutions SO2 technology using on existing Wet and Precipitators Catalytic
• Utilizing reagents such ammonia as the reagent Dry FGD • Fabric Filters Reduction (SCR)
as lime, limestone, and • Valuable crop fertilizer by • Aftermarket services • Associated parts technology
product provides pay back for Wet and Dry FGD and upgrade and
sodium licensed through
to owner systems repair services
• Worldwide installations Termokimik
• Commercially • Engineering studies • Engineering
demonstrated for over • Field advisory services studies • Reduces more
International than 90% of NOx
seventeen years. and training • Field advisory
FGD
• Operating Units in U.S.A., services and from flue gas
Licensing emissions and
Canada, China and Poland training
• MET licenses the right to use showcases a
MET technology in multiple solid installation
international markets base around the
world
* FGD upgrade and associated services are not included in the total megawatt listing to avoid duplicity.

MET FGD Global Presence
India
Germany United States
France Japan
Canada
Netherlands
China
United Kingdom
Philippines
Finland Taiwan
Korea
Poland
Austria Viet Nam
Israel
Brazil
Slovenia
Italy
Slovakia Croatia
Czech Saudi
Republic Arabia

Licensee Program
International Licensee program has been a cornerstone of the company’s
History
ALSTROM
KVAERNER JOHN BROWN
STEINMUELLER DOOSAN
HTS KRJS CHEC
EMIT TIANCHENG
AE&E MITSUI MIIKI
HAMON RESEARCH COTTRELL TERMOKIMIK
FOSTER WHEELER SPAIN SICHUAN ENTECH
SEPEC IHI
ECE
THERMAX SHANDA WIT
WUHAN KAIDI
QINGDAO HUATUO

Licensee Program
Many of the present and past European based FGD companies were
one-time Chemico/GEESI/MET Licensee
• L.C. Steinmueller - Germany
• Termokimik - Italy
• Kvaerner John Brown - United Kingdom
• Austrian Energy & Environment – Austria & Eastern Europe
• Hoogovens – Netherlands
• Hamon – France & USA
• Foster Wheeler – Spain
• Alstrom – France
• EMIT – Italy

Licensee Program
The expansion of the Licensee program into Asia began

in the late 1980s
• IHI – Japan
• Mitsui Miiki – Japan
• Doosan Heavy Industries – Korea
• CHEC – China
• ECE – China/USA
• Shangda Wit – China
• Sino Tiancheng – China
• Sichuan Entech – China
• SEPEC – China
• KRJS – China
• Tiancheng – China
• Wuhan Kaidi - China
• Thermax – India

Licensee Program
The original Chemico/GEESI open tower with In-Situ Forced

Oxidation air system was the basis for most of the present open
spray tower designs

AGENDA
Overview of the WFGD

Process
Basic Chemistry
Typical FGD Processes
Equipment Components
Summary

Wet Scrubber Basic Configuration

Reagents
All wet flue gas desulfurization (FGD) require use of an

alkaline chemical “reagent”
Limestone
Lime
Sodium
Ammonia
Dual Alkali
Seawater
Typical Reagent for Coal Fired FGD systems

Byproducts
Gaseous SO2 is convert to either a solid by-product or a

liquid waste stream
Gypsum Based process
Most widely used internationally
Throwaway process
Sodium and Un-oxidized Calcium
Fertilizer product process
Regenerative process

Wet Scrubber Design
• SO2 – Sulfur Dioxide - Will be readily absorbed Flue Gas Outlet

• 96+% removal efficiency
• Converted to Calcium Sulfate - Gypsum
• HCl – Hydrogen Chloride - Will be easily absorbed
Mist Eliminators
• 99+% removal efficiency and Wash Sprays
• Converted to Calcium Chloride
• High solubility
• HF – Hydrogen Fluoride - Will be easily absorbed
Flue Gas Inlet
• 99+% removal efficiency SO2, HCL, HF,
Absorption Sprays
• Converted to Calcium Fluoride SO3 & Ash
• High solubility
• SO3– Sulfur Trioxide - Will be partially absorbed Liquid Level
• ~20-50% removal efficiency
• Converted to Calcium Sulfate and H2SO4
aerosol
Sparger
• Fly Ash - Will be partially removed
• ~30-70% removal efficiency Agitator
• Can impact Product Purity
Recycle Pumps
(As Required)

Process
Basic Chemistry
Typical FGD Processes
Summary

Limestone Based FGD Chemistry
Reactions taking place in limestone based system: in the absorber & recycle tank:
1. SO2 + H2O H2SO3 Absorption

2. CaCO3 + H2SO3 CaSO3 + CO2 + H2O Neutralization
3. CaSO3 + ½ O2 CaSO4 Oxidation
4. CaSO3 + ½ H2O CaSO3 + ½ H2O Crystallization
5. CaSO4 + 2H2O CaSO4 . 2H2O Crystallization
SO2 O2
H2O
CaCO3
Gypsum
Wet Scrubber Fundamentals

Process
Basic Chemistry
Typical WFGD
Processes
Summary

Typical WFGD Design
Operations and Design
Operations
Gas distribution & wet/dry interface at
Inlet ALRD
Gas-Liquid contact in spray zone
ALRD – Wall Rings
Liquid-Gas separation with mist
eliminators
Oxidation & dissolution in reaction tank
System Design
Low lifecycle cost
High availability

ALRD – Absorber RE-Distribution Device
ALRD Approach: United States Patent

Brown et al.
• Developed by MET and patented in
Patent No.: US 6,550,751 B1
2003 Date of Patent: April. 22, 2003
• Positioned, as needed below select
spray levels
GAS-LIQUID CONTRACTOR WITH LIQUID REDISTRIBUTION
• Mitigate gas “sneakage” along DEVICE
absorber walls Inventors: Gregory Norman Brown, Palmyra, PA
(US); Raymond Raulfs Gansley,
• Re-introduce slurry from walls back into Lebanon, PA (US); Michael Lyn
the absorption spray zone Mengel, Fredericksburg, PA (US); Eli
• Increased pressure drop is negligible Gal, Lebanon, PA (US)
Assignee: Marsulex Environmental Technologies
• Dramatically improves SO2 removal Corp., Lebanon, PA (US)
Notice: This patent issued on a continued prosecution
MET also holds international patents application filed under 37 CFR 1.53(d), and is subject to the
twenty year patent term provisions of 35 U.S.C. 154(a)(2).
for the ALRD® technology in Austria,
Canada, Germany, Italy, Japan, Korea,
Netherlands, Poland and United
Kingdom

Sneakage of partially untreated flue gas due to poor liquid/gas contact, poor gas
distribution and uneven spray density accounts for the majority of SO2 emissions
Sneakage Correction Options:

600
SO2 Concentration, ppm

B.L England, 36 ft
- “Brute force” approaches, such as: 500 Petersburgh, 46 ft
• Higher L/G (higher pump power) 400
• Perforated trays/packing (higher 300

system gas pressure drop)
200
OR 100
- Engineered optimization of open spray 0
tower design utilizing MET ALRD® technology 1 2 3 4 5 6 7 8 9
Distance from Wall, ft

Original design - left and Retrofit - on the right ALRD® installations

First unit installed in 1998 at Dakota Gasification Company in FRP
absorber vessel

Typical Absorber Design Considerations
Open Spray Tower
Considerations
Outlet Emissions Criteria

Required Gypsum Purity
Nominal 3.0 – 4.0 mps
saturated gas velocity
Recycle Residence Time of
minimum of 3.5 minutes
Solids Residence Time of
12-15+ hours
Minimum Oxidation
Stoichiometry of 2
Desired Absorber
Stoichiometry

WFGD Terminology & Process Impacts
SO2 Outlet
Emissions
pH and
Density Stoichiometry
Liquid to
Residence Gas Ratio
Time
Oxidation

Typical WFGD Terminology
SO2 Emissions
• Allowable SO2 outlet emissions are based on Local, Region and or National
regulations. Theses are the minimum standards in the design
• Requirements dictated by environmental regulations can be in many different
terms
– % Removal – Removal efficiency – the actual decrease in SO2 inlet
compared to the outlet.
– PPM – parts per million – is a concentration
– kg/hr – kilograms per hour – actual quantity on an hourly basis
– kg/kj – kilograms per kilojoules units- kilograms based on the amount
of heat generated
• Depending on requirements, absorbers may be designed to meet any number
of these variables

Stoichiometry & pH
Stoichiometry – the number of moles of SO2 removed per mole of
reagent consumed in the chemical reaction.
pH is the measurement of the acidity or alkalinity in a solution, slurry
pH is likely the most important control variable for absorber operation
pH controls the amount of reagent feed into the process
pH is indirectly related to the ability of the droplets to absorb SO2 so
pH can control removal efficiency of the Absorber
pH is related to reagent stoichiometry – higher than require pH
increases the amount of excess Calcium in the system

Liquid-to-Gas Ratio
L/G is the ratio of recycle slurry (in l/hr) to absorber outlet gas flow (m3/hr,
actual)
The amount of surface system available for reaction with SO2 is determined
by L/G
L/G ratio can be changed by altering either recycle flow rate or flue gas flow
rate
The greater the L/G the higher the system removal efficiency, there are
more droplets contacting the SO2 in the gas to facilitate absorption.

Oxidation
Is the conversion of Sulfite to Sulfate by the introduction of air
into the absorber vessel reaction tank
Quantity of air and reaction tank size is based on the
maximum SO2 removal rates for the absorber
Is dictated by the oxygen transfer rate
Volume of liquid above the air introduction location is equal to
or greater than volume needed for oxygen transfer from gas to
liquid.

Residence Time
The time that slurry spends in the reaction tank before
being recycled for further SO2 absorption
Residence time allows for the complete oxidation reaction
to take place
Complete oxidation ensures the liquid is not super-
saturated and avoid scaling in lime/limestone systems
Typically, for limestone systems, a minimum residence
time of a of 3.5 minutes is provided

Density
The quantity of solids in the recycle slurry measured on a
by weight basis
Solids concentration referred to as Total Suspended
Solids –TSS
Typical operational TSS in the absorber system is 15 to
20%.
Residence time allows the liquid to de-supersaturate and
avoid scaling in lime/limestone systems
Typically, for limestone systems, a minimum recycle
residence time of 3.5 minutes is provided

Process
Basic Chemistry
Typical WFGD Processes
Summary

Typical WFGD Equipment
To Vacuum
Belt Filter
Limestone Slurry

Spray Headers
Absorber Recycle
Spray Headers can be
Stainless Steel,
Fiberglas Reinforced
Plastic (FRP,
sometimes called
GRP), alloy or rubber
lined carbon steel
May be self or
internally supported
Absorber Spray Levels
Milton R. Young | Center, North Dakota

Spray Headers
Absorber Recycle Spray

Headers have a high level
of overlap
150 to 250% overlapping
of spray nozzle patters in
common
Spray nozzles made of
silicone carbide material

Mist Eliminators
Mist Eliminator Mist Eliminator Wash System

Improvements

Mist Eliminators
Purpose
Removal of entrained slurry and water droplets
Supply a tortuous path for airborne droplets to facilitate removal

ALRD - Wall Rings
ALRD installed into Tile lined vessels

Recycle Pumps
Centrifugal Horizontal End Suction
Pump – can be alloy ceramic or
rubber lined
Up to 20,000 m3/hr flow rates
Use of Mechanical Seal eliminates
the need for seal water

Agitator and Oxidation Air Lance
Agitator with Air Lance in Operation
Oxidation Air Compressors
Photo courtesy of Ekato

Absorber Solids Concentration and Primary Dewatering Systems
Hydroclone Overflow
1-2% Solids
3-5% CaCO3
Hydroclone Feed Vortex Finder

15-20% Solids
1-3% CaCO3
APEX
Hydroclone Underflow
55% Solids
0.5-1.5% CaCO3

Absorber Solids Concentration and Primary Dewatering Systems
Slurry Solids Concentration

Solids concentration is maintained by
placing the hydroclones into service and
removing them from service based on
predetermined density set points.
Higher Absorber solids concentration in the

FGD system can produce:
Improved gypsum relative saturation

and minimize scaling
Can maximized gypsum crystal growth
Can enhanced CaCO3 effects due to

increased dissolution time

Primary Dewatering System
From Primary From Primary

Hydroclones Hydroclones

Secondary or Final Dewatering
Secondary Dewatering – Belt Filter

Solids concentration is maintained by
setting the speed and thickness of
cake on the belt filter
The moisture from a belt filter design
is ~10% by weight
The vacuum on the belt is held
constant
The gypsum particle size and the
amount of flyash in the system will
affect the filter performance
Feed solids concentration needs to be
consistent via the hydroclone
performance to ensure repeatable
results from the filter

Secondary Dewatering - Vacuum

Pump
Vacuum pump skid is fixed speed with
no variability in performance
Utilizes a Liquid Ring Vacuum Pump,
seal water must be maintained at all
times.
Secondary Dewatering – Vacuum

Receiver
Vacuum receiver is the tank where the
filtrate once drawn from the gypsum product
is accumulated

Gypsum Storage

Final Product Handling

Final Gypsum product is typically
conveyed to or dumped into pile/s in
the dewatering building or adjacent
stack out areas
The Gypsum product is loaded with
large front-end loading equipment
and then into trucks for final
distribution

Limestone Preparation

Limestone Preparation Systems

Limestone is typically delivered by
Truck or Rail
The limestone can be stored on grade
or in silos
Unloading of limestone is done
mechanically via loaders and conveyors

Limestone Preparation Systems

Limestone is weighed before being
added to the ball mill and an
appropriate amount of water is
metered into the ball mill.

Horizontal Ball Mill

Most prevalent method of grinding
limestone in the FGD industry
The mill is filled with steel balls that
vary in size up to 50 mm in diameter
Limestone is added to the mill with
water and the mill rotates at a fixed
speed

The product from the grinding overflows out the mill and is then
processed in hydroclones

Hydroclone Classifiers
– Hydroclones are used to classify the final
product, ensure it is the proper size
– The desired grind for limestone is 95%
passing 325 mesh for most applications
– Most lime applications do not require
Hydroclones

Process
Basic Chemistry
Typical WFGD Processes
Summary

Lower Colorado River Authority
2x600 MW | Limestone WFGD
The LCRA project is MET’s first application of Stebbins tile with carbon steel absorber vessels.
Fuel: PRB Coal
% Sulfur: 0.8%
Inlet Gas Volume: (Nm3/hr) 2,500,000

Reagent: Limestone
Absorber Type: Spray Tower
SO2 Removal Efficiency: 97%
Startup Date: Unit 1: Jan 2011

Unit 2: Apr 2011
Fayette Power Project, Units 1, 2 and 3 | Texas

PacifiCorp Energy
Hunter Units 1 & 2 and Huntington Canyon Unit 1
• Each unit is 430+ MW rated

• Substantial completion dates:
– Huntington Unit 1: July 2011
– Hunter Unit 2: September 2011
– Hunter Unit 1: May 2013
Fuel: Coal
% Sulfur: 1.3%
Reagent: Lime
SO2 Removal Efficiency: 95.75%
Startup Date: Noted above

Israel Electric Corporation
2 x 575 MW | Limestone WFGD

Orot Rabin is Israel’s largest power complex and represents nearly 25% of IEC’s total generating
capacity.
Fuel: Coal
% Sulfur: 1.2%
Inlet Gas Volume: (Nm3/Hr) 1,990,000
Reagent: Limestone
SO2 Removal Efficiency: 95.6%
Startup Date: Q4 2012
Orot Rabin, Units 5 & 6| Israel

Dominion Energy
3 x 535 MW
The Mt. Storm Unit 3 project execution was such a success that Dominion Energy exercised
options for two more MET FGD systems at Units 1 and 2 on a collaborative, open book basis.
Fuel: Bituminous Coal
% Sulfur: 2.2%
Reagent: Limestone
SO2 Removal Efficiency: 95%
Mt Storm Units 1&2 | West Virginia


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NTPC Rihand Power Station

Wet Flue Gas Desulfurization - Process Overview

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Traditional Ammonium Sulfate FGD Upgrades Selective

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Austria Viet Nam

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

The expansion of the Licensee program into Asia began

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

The original Chemico/GEESI open tower with In-Situ Forced

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Overview of the WFGD

Typical FGD Processes

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

All wet flue gas desulfurization (FGD) require use of an

Typical Reagent for Coal Fired FGD systems

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Gaseous SO2 is convert to either a solid by-product or a

Gypsum Based process

Most widely used internationally

Sodium and Un-oxidized Calcium

Fertilizer product process

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

• SO2 – Sulfur Dioxide - Will be readily absorbed Flue Gas Outlet

• Converted to Calcium Fluoride SO3 & Ash

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Typical FGD Processes

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

1. SO2 + H2O H2SO3 Absorption

Overview of the WFGD

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Operations and Design

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

ALRD Approach: United States Patent

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Sneakage Correction Options:

SO2 Concentration, ppm

• Higher L/G (higher pump power) 400

• Perforated trays/packing (higher 300

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Original design - left and Retrofit - on the right ALRD® installations

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Outlet Emissions Criteria

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Typical WFGD Processes

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Copyright © 2022 | MET – Marsulex Environmental Technologies | All rights reserved

Absorber Recycle Spray

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