NEW FLUE GAS TREATMENT SYSTEM FOR 1,050 MWe COAL ...

NEW FLUE GAS TREATMENT SYSTEM
FOR
1,050 MWe COAL FIRED PLANT
Babcock – Hitachi K.K.
Babcock-Hitachi K.K.

CONTENTS
1. Plant Condition
2. New Technologies and Features
3. Plant Operating Results
4. Conclusion
Babcock-Hitachi K.K.

CONTENTS
1. Plant Condition
2. New Technologies and Features
2. New Technologies and Features
3. Plant Operating Results
3. Plant Operating Results
4. Conclusion
4. Conclusion
Babcock-Hitachi K.K.

1. Plant Condition
Table Major Conditions of New Flue Gas Treatment System
for Tachibanawan Thermal Power Plant unit 2
Items
Specifications
Capacity (MW) 1,050
FGD
GGH
ESP
Wet Limestone-Gypsum Process
Non Leak Type Heat Medium Forced Recirculated
Low Temperature Type
Air Preheater Outlet
FGD Outlet
Flue Gas Flowrate (m 3 N/h)
3,330,000 3,470,000
Dust Conc. (mg/m 3 N) 20,000 10
SO2 Conc. (ppm) 809 50
Gas Temp. (deg.C) 130 90
Babcock-Hitachi K.K.

1-11 Photo of Plant
STACK
GGH
Reheating
Absorber
ESP GGH
Heat Recovery
BOILER
Site View of EPDC/TACHIBANAWAN No.2 UNIT
Babcock-Hitachi K.K.

1-22 Flow Diagram of New Flue Gas Treatment System
Mist Eliminator
GGH
Stack
(Reheater)
From Air
Preheater
GGH
(Heat Recovery)
ESP
IDF
Absorber
Propeller
Atomizer
Air
Recirc.
Pump
CaCO3 Monitor
Limestone
powder
From Air
Preheater
GGH
(Heat Recovery)
ESP
IDF
GGH
Heat Medium
Circulation Pump
To Waste
water
Treatment
Belt Filter
Gypsum
Filtrate Pit
Waste water Pit
Absorbent
Pit
Babcock-Hitachi K.K.

CONTENTS
1. Plant Conditions
1. Plant Conditions
2. New Technologies and Features
3. Plant Operating Results
3. Plant Operating Results
4. Conclusion
4. Conclusion
Babcock-Hitachi K.K.

2. New Technologies and Features
(1) New Flue Gas Treatment System
(2) Compact Spray Absorber
(3) Heat Medium Forced Circulated Type GGH
Babcock-Hitachi K.K.

2. New Technologies and Features
(1) New Flue Gas Treatment System
(2) Compact Spray Absorber
(2) Compact Spray Absorber
(3) Heat Medium Forced Circulated Type GGH
(3) Heat Medium Forced Circulated Type GGH
Babcock-Hitachi K.K.

2-1-11 Comparison of Flue Gas Treatment System
CONVENTIONAL SYSMTEM
Boiler SCR AH ESP GGH FGD GGH
IDF BUF Stack
Gas Temp. (deg.C) 130 130 90 50 90
Dust Conc. (mg/m 3 N) 20,000
100
100 20
20
NEW FLUE GAS TREATMENT SYSTEM
Boiler SCR AH GGH ESP FGD GGH
IDF BUF Stack
Gas Temp. (deg.C) 130 90 90 50 90
Dust Conc. (mg/m 3 N) 20,000 20,000 50 10 10
Babcock-Hitachi K.K.

2-1-22 Feature of New Flue Gas Treatment System
1. Stable high dust removal performance in ESP
(Low gas temperature in ESP)
2. No plugging and corrosion caused by SO3 condensation in
GGH heat recovery section
(Higher dust concentration circumstance)
3. Higher Gypsum purity due to lower inlet dust concentration.
Boiler SCR AH GGH ESP FGD
Babcock-Hitachi K.K.
GGH
IDF BUF Stack
Gas Temp (deg.C) 130 90 90 50 90
Dust Conc. (mg/m 3 N) 20,000 50 10 10
20,000

2-1-33 Gas Temperature Effect for ESP Performance
Decrease of ESP
Inlet Gas Temp.
Decrease of Dust
Electric Resistant
Improve of
ESP Performance
New Flue Gas System
Conventional System
Dust Electric Resistant
(ohm cm)
Low S Coal
High S Coal
50 100 150 200
Temperature (deg.C)
Babcock-Hitachi K.K.

2-1-22 Feature of New Flue Gas Treatment System
1. Stable high dust removal performance in ESP
(Low gas temperature in ESP)
2. No plugging and corrosion caused by SO3 condensation in
GGH heat recovery section
(Higher dust concentration circumstance)
3. Higher Gypsum purity due to lower inlet dust concentration.
Boiler SCR AH GGH ESP FGD
Babcock-Hitachi K.K.
GGH
IDF BUF Stack
Gas Temp (deg.C) 130 90 90 50 90
Dust Conc. (mg/m 3 N) 20,000 50 10 10
20,000

2-1-44 Circumstance of Heat Recovery Section
100000
Expected operation range
Dust Concentration (mg/m 3 N)
Dust Conc. (mg/m 3 N)
10000
1000
100
10
DRY Area
WET Area
DRY - WET Boundary Line
1
0. 1 1 10 100 1000
SO3 Concentration SO 3 (ppm)
Babcock-Hitachi K.K.

2-1-22 Feature of New Flue Gas Treatment System
1. Stable high dust removal performance in ESP
(Low gas temperature in ESP)
2. No plugging and corrosion caused by SO3 condensation in
GGH heat recovery section
(Higher dust concentration circumstance)
3. Higher Gypsum purity due to lower inlet dust concentration.
Boiler SCR AH GGH ESP FGD
Babcock-Hitachi K.K.
GGH
IDF BUF Stack
Gas Temp (deg.C) 130 90 90 50 90
Dust Conc. (mg/m 3 N) 20,000 50 10 10
20,000

2-1-55 Pilot Plant Test Facility
Boiler
EP
IDF
SCR A/H FGD
SCR
BUF
Gas Cooler
GGH
ESP
IDF
FGD
GGH
Pilot Plant
Actual Flue Gas 2,000m 3 N/h Pilot Test Facility
(at Matsuura P.S / E.P.D.C.)
Babcock-Hitachi K.K.

2. New Technologies and Features
(1) New Flue Gas Treatment System
(1) New Flue Gas Treatment System
(2) Compact Spray Absorber
(3) Heat Medium Forced Circulated Type GGH
(3) Heat Medium Forced Circulated Type GGH
Babcock-Hitachi K.K.

2-2-11 Feature of Compact Spray Absorber
Technology
Effect
Gas
Outlet
High Gas
Velocity
High Eff.
Compact
Horizontal Flow
Mist Eliminator
Slimmer
Gas
Inlet
Φ16,400
27,700
High Density
Spray
High Slurry
Concentration
Lower
Height
One Absorber for
1,050MW Boiler Flue Gas
Babcock-Hitachi K.K.

2-2-22 SO2 Removal Performance Results in Pilot Plant
Removal Eff. (%)
SO2 Removal Eff. (%)
SO
V=7m/s
5m/s
3m/s
5 10 15 20
L/G (L/m 3 N)
Babcock-Hitachi K.K.

2-2-33 Two-Film Theory for SO2 Absorption
Gas Film
SO 2
K G :Overall Mass Transfer Coefficient
(kgmol/m 2 hatm)
k G : Gas Side Mass Transfer Coefficient
(kgmol/m 2 hatm)
k L :Liquid Side Mass Transfer Coefficient
(m/h)
k G
1 1 H
= +
K G k G k L
Liquid Film
Droplet
k L
2
(kgmol/mh atm, m/h)
Mass Transfer Coefficient
10 3 K G
K L
10 2
10
1 10 100
Gas Velocity (m/s)
Babcock-Hitachi K.K.

2-2-44 Particle’s s Behavior in Spray Droplet
Ar Laser
Spectra Scope
Laser
Droplet
Phase Doppler
Tachometer
Glass Stick
Gas
Drople
t
Detector
Particle 液 滴 Velocity 内 部 粒 in 子 Droplet 速 度 (m/ (m/s)
0.3
0.2
0.1
0
石 膏
Gypsum
Improved
Mixing
混 合 促 進
0 5 10 15
Gas ガス 流 Velocity 速 (m/ (m/s)
Babcock-Hitachi K.K.

2-2-55 Effect of High Gas Velocity for SO2 Removal
Droplet
Lower Gas
Velocity
Covered by
SO2 Phase
Liquid
Improved
internal mixing
Higher Gas
Velocity
Increase of SO2 removal
performance due to droplet
surface mixing enhancement.
2
(kgmol/m h atm, m/h)
Mass Transfer Coefficient
10 2
10
Gas Velocity
K G
K L
(m/s)
10 3 1 10 100
Babcock-Hitachi K.K.

2. New Technologies and Features
(1) New Flue Gas Treatment System
(1) New Flue Gas Treatment System
(2) Compact Spray Absorber
(2) Compact Spray Absorber
(3) Heat Medium Forced Circulated Type GGH
Babcock-Hitachi K.K.

2-3-11 Feature and Special Consideration for GGH
Heat Medium Heater
Steam
From AH
GGH Heat Recovery
Section
From Absorber
To ESP
GGH Reheater Section
High Dust Condition
SO3 Concentration
Vapor Condensation
Low pH & High Cl
mist from Absorber
Abrasion
Plugging
Corrosion
Corrosion
SCC
Heat Medium Circulation Pump
Optimization of Fin Pitch, Gas Velocity
Evaluation of Dust / SO 3
ratio
Control of Temperature (Heat medium)
Optimum Material Selection
Babcock-Hitachi K.K.

2-3-22 Transportation of GGH Module
GGH Module (Reheater Section)
GGH Module (Heat Recovery Section)
Babcock-Hitachi K.K.

CONTENTS
1. Plant Conditions
1. Plant Conditions
2. New Technologies and Features
2. New Technologies and Features
3. Plant Operating Results
4. Conclusion
4. Conclusion
Babcock-Hitachi K.K.

3-11 Performance Test Results (Emission Parameter)
Item
Design
Actual
ESP Inlet Dust Conc. (mg/m 3 N)
Stack Inlet Dust Conc. (mg/m 3 N)
Absorber Inlet SO2 Conc. (ppm)
Stack Inlet SO2 Conc. (ppm)
Inlet Gas Temp. (deg.C)
Stack Inlet Gas Temp. (deg.C)
20,000 17,600

3-22 The State of the Heating Tubes after Operation
Pressure Loss of GGH (kPa)
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
Heat Recovery Side
Reheating Side
2000/3 2001/3 2002/3 2003/3 2004/3
Time
after 2 years operations
(Heating Tube of GGH)
Babcock-Hitachi K.K.

3-33 By-Product Gypsum Composition
Item
Design Actual
Purity (%) ≧ 90 99
Surface Moisture (%) ≦ 10 8
CaCO3 (%) ≦ 1.1 0.1
CaSO3 ・1/2H2O (%) ≦ 0.2 0.1
50μm
Babcock-Hitachi K.K.

CONTENTS
1. Plant Conditions
1. Plant Conditions
2. New Technologies and Features
2. New Technologies and Features
3. Plant Operating Results
3. Plant Operating Results
4. Conclusion
Babcock-Hitachi K.K.

4 Conclusion
We, Babcock-Hitachi, adopted various new technologies to
Tachibanawan Thermal Power Plant unit 2 and confirmed
all values are satisfied with the design values.
- New Flue Gas Treatment System
- Compact Spray Absorber
- Heat Medium Forced Circulated Type GGH
- On-line CaCO3 Analyzer
We continue further studies in rationalization with a view to
higher efficiency and a more assured environmental
conservation program.
Babcock-Hitachi K.K.