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FGD Presentation (ILFS)

This document provides an overview of the flue gas desulfurization (FGD) system at a 2 x 600 MW coal-based thermal power plant in Cuddalore, Tamil Nadu. The FGD system uses a wet limestone scrubbing process to remove over 95% of sulfur dioxide from flue gases before release. It features absorbers, a gas-gas heat exchanger, booster fans, slurry systems, and waste water treatment. Construction included over 1000 piles and 12,000 cubic meters of concrete. The FGD is designed to handle sulfur content of 0.8% in coal at full load.

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proloy12
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524 views40 pages

FGD Presentation (ILFS)

This document provides an overview of the flue gas desulfurization (FGD) system at a 2 x 600 MW coal-based thermal power plant in Cuddalore, Tamil Nadu. The FGD system uses a wet limestone scrubbing process to remove over 95% of sulfur dioxide from flue gases before release. It features absorbers, a gas-gas heat exchanger, booster fans, slurry systems, and waste water treatment. Construction included over 1000 piles and 12,000 cubic meters of concrete. The FGD is designed to handle sulfur content of 0.8% in coal at full load.

Uploaded by

proloy12
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 40

Flue Gas Desulphurization (FGD) plant

2 x 600 MW Coal based Thermal power


plant Cuddalore, Tamil Nadu.

By MK Parameswaran
23rd Dec, 2016
Introduction

Flue Gas Desulfurization is a process of removing Sulphur


from flue gas of Thermal power plant before it is released
into the atmosphere.

2
Introduction contd..

IL&FS Tamilnadu Power Co. Ltd, uses Limestone Wet


Spray type Flue Gas Desulphurisation system.

Our wet FGD system, also called a wet scrubber system,


is based on the principle that limestone, in the form of
slurry is brought into contact with the flue gas which
absorbs the SO2 in it.

Our FGD is designed for 100% BMCR condition with


sulphur content 0.8% in Coal and desulfurization efficiency
≥95%.

3
Salient Features
 Wet Type Desulphurisation System Consist Of :

 Absorber
 Gas To Gas Heat Exchanger (GGH)
 Booster Fan
 Slurry System
 Gypsum De-hydration & Waste Water Treatment System
 Ducting System
 Electrical And Instrumentation

4
FGD Process Diagram

GAS TO GAS
HEAT EXCHANGER

BOOSTER FAN

5
Overview of FGD

6
Construction details

 NUMER OF PILES

 UNIT # 1 & COMMON SYSTEMS : 773 Nos.


 UNIT # 2 : 280 Nos.
Total : 1053 Nos.

 RCC QUANTITY

 UNIT # 1 & COMMON SYSTEMS : 9000 Cu.M.


 UNIT # 2 : 3000 Cu.M.
Total : 12000 Cu.M.

7
Construction details

 STRUCTURAL STEEL

 UNIT # 1 & COMMON SYSTEMS : 2500 MT


 UNIT # 2 : 1000 MT
Total : 3500 MT

 EQUIPMENTS

 UNIT # 1 & COMMON SYSTEMS : 2500 MT


 UNIT # 2 : 1000 MT
Total : 3500 MT

8
Absorber details
 Absorber is the main equipment where the sulphur is
removed from flue gas.

 It is a 41.5 M Height shell of 17.6 M. Dia and total


weight of 510 MT

 The internal surface is coated with anti corrosion paint


up to 4 mm thickness to protect from corrosion.

 The external surface is protected with thermal


insulation.

 The limestone slurry is sprayed inside the absorber


through the spray headers and nozzles which comes in
contact with the flue gas passing through it and
removes the sulphur in it. 9
Absorber construction

PILES FOR ABSORBER


10
Absorber construction

11
Absorber construction

12
Absorber construction

13
Absorber construction

14
Absorber construction

15
Booster Fan

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Gas to Gas Heat Exchanger

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Tanks

18
Wet Ball Mills

19
Limestone Slurry Tanks

20
Slurry Recirculation Pumps

21
Limestone Silo/Bucket Elevator

22
Gypsum Dehydration

23
Gypsum Dehydration System

24
Chemical Process

FLUE GAS WITH

SLURRY
System Description

• The main task of the absorber is to remove sulfur dioxide


from flue gas and to produce gypsum as a disposable product.
• The gas flows upwards through the absorption zone and is
washed counter currently by a spray of slurry droplets,
containing suspended gypsum and limestone for the reaction
with SO2.
• Finally the formed sulfate and calcium ions crystallize in the
absorber recycle tank as a gypsum.
• Gypsum will be dewatered and the waste water will be again
treated and reused in the process .
• Final waste water will be again treated suitably and
discharged with recommended quality.

26
Slurry Pumps

SLURRY RECIRCULATION
PUMP HOUSE

SLURRY RECIRCULATION
PUMP VIEW

27
Absorber System
“C“

“D“

“B“

“A“

28
Limestone Slurry System

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Limestone Slurry Process

• The Wet Ball Mill system ensures lime stone crushing upto
particle size of 44 micron (325 mesh - 90%).
• Hydro cyclone is used to separate the limestone slurry at the
wet Ball Mill outlet.
• Each set of mill is equipped with a group of limestone slurry
hydro cyclones, and can meet the requirement of limestone
slurry fineness.
• Concentration of limestone slurry can be correctly controlled
in any concentration upto 25-30％wt.

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Wet Ball Mills

WET BALL MILL WITH


RECIRCULATION SYSTEM

WET BALL MILL

31
Gypsum Slurry Dehydration

32
Gypsum Slurry Dehydration
Vacuum belt Feeder Cloth wash process

Hydro cyclone Cake wash process

33
Gypsum Slurry Dehydration

• The system is common for both units. The main equipments


include 2 gypsum hydro cyclones, 2 vacuum belt filters, 2
vacuum pumps, 2 set of filter water system.
• Each vacuum belt filter and hydro cyclone will be based on the
capacity of 100% BMCR worst coal condition.
• Gypsum Slurry from Absorber flows into the gypsum hydro
cyclone to be concentrated. Moisture of the gypsum cake is
about 10%.
• The overflow of hydro cyclone split into two categories: one
part be transported to the filtrate water tank, the other parts
flow into the waste-water tank and be transported to waste
water hydro cyclone.

34
Process water quality

SI.NO. Description Unit Value


1 Total Dissolved Solids (TDS) Ppm 350-500
2 Calcium Ppm 1.5
3 Magnesium Ppm 3.5
4 Potassium Ppm 6.5
5 Bicarbonates Ppm 2.0
6 Chlorides Ppm 215
7 Sulphates Ppm 5.0
8 Nitrates Ppm 0.1
9 Boron Ppm 1.2
10 Silica Ppm 0.1
35
Water Requirement
Process Water input : 100 TPH per FGD.
TPH
Process water Waste water discharge 9.8
Process water Gypsum Cake 10% moisture 1.7
Chemical water Gypsum Cake 3
Saturated water Clean gas - evaporation 39.6
Clean gas - Mist eliminator (evaporation
Process water 0.155
or carryover)
Process water Sludge treatment system Consumption 0.084
Water consumed by Dissolved soluble
Chemical water 0.071
substances
Total break up 54.41

36
Other details…
Total Auxiliary power consumption for the FGD plant at 100%
TMCR condition on firing worst coal is less than 23902 KW, for
the two FGD units with common auxiliary facilities.

Limestone consumption per FGD at 100 % TMCR Condition on


firing worst coal is less than 3.8TPH.

Gypsum production per FGD 6.0 TPH

37
Lime Stone Quality

SI.NO. Constituents Unit % by Weight


1 Silica as SiO2 % 4-6
2 Iron as Fe2O3 % 1.5-2.2
3 Aluminium as Al2O3 % 1.8-2.8
4 CaCO3 %
85-89（CaCO3>85%）
5 MgCO3 %
6 Acid Insoluble % Below 1%
7 Others %
Inherent Moisture
8 %
Content
9 Bond Work index KWH/T 13
10 Raw limestone size mm ≤20
38
Waste Water System
FGD system will produce a small amount of waste water, The
main task of the waste water treatment plant is to adjust the pH
and to remove the heavy metals and suspended solids.

The final out put of WWS will be as below always

DESIGN:
pH - 6-9
Residual chlorine - 0 ppm
Oil and grease - ＜ 1 ppm
Effluent quantity discharge for 2 units - ＜ 24 m3/h

39
 THANK YOU 

40

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