85 D 7 B 94

Introduction of Babcock-Hitachi K.K.
Wet Flue Gas Desulphurization System

March 12, 2012
Babcock-Hitachi K.K.
Promising to contribute to global welfare
with technologies of energy and environment systems
All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.
1. General Information
Babcock-Hitachi in HITACH Group

President
President
Mr. Hiroaki Nakanishi
Corporate
CorporateStaff
Staff
Intellectual
IntellectualProperty
PropertyDivision
Division
R&D
R&DDivision
Division
Mr. Tetsuro Wakino
Babcock
Hitachi
Babcock
Hitachi
(100% Owned)
(100% Owned)
Power
PowerSystems
Systems
Company
Company
Thermal
ThermalPower
Power
Systems
Division
Systems Division
Industrial
Industrial&&Social
SocialInfrastructure
InfrastructureSystems
SystemsCompany
Company
Information
Information&&Control
ControlSystems
SystemsCompany
Company
Urban
UrbanPlanning
Planning&&Development
DevelopmentSystems
SystemsCompany
Company
Boiler
Boilerand
andAir
AirQuality
QualityControl
Control
Systems
SystemsDivision
Division
Hydroelectric
HydroelectricPower
Power
Systems
Division
Systems Division
Nuclear
NuclearSystems
SystemsDivision
Division
Power
Power&&Industrial
Industrial
Systems
SystemsDivision
Division
Power Systems Company of HITACHI

Thermal Power Business
Coal Fired PP
CO2 Capture Solution
AQCS
Gas Turbine
60%
FY2010
SALES
813.2B
(ABWR, ESBWR)
20%
GTCC, Preventive Maintenance, etc.
Wind Power Sys. Solar Power Sys.
20%
Power Device
Major Equipment
Nuclear Equipment
RPV
Central Control Panel
Hydro Power Sys.

PBT
Smart Grid,
Transmission &
Distribution
System
PET Service, etc.
Preventive Maintenance, Fuel Cycle, etc.
Nuclear Power Business

Others

Blue : Products of BHK
Outline of Babcock-Hitachi K.K.

- Established
1953
- Employees
(Worldwide)
3,200
- Head Office
Tokyo, Japan
Segment of
Power & Environmental
in Hitachi group
Stock holder: Hitachi Ltd.
(100%)
- Works
Kure 1st & 2nd, Noumi, Akitsu
Philippine (BHPI), China (BHDB)
- Laboratories
Kure, Akitsu
- Affiliated Companies
Domestic : 2 / Overseas :3
- Quality Certificates
ISO 9001, ISO 14001,
ASME S, U and U2
Company History
Hitachi, Ltd.
B&W UK
Zenma Works Ltd.
established
1908
1927
1928
1953
1959
1961
1964
1965
1971
1975
1978
Hitachi Works Boiler Manufacturing

Department established
Corporate name changed to
Toyo Babcock Ltd.
Babcock-Hitachi established
Hitachi Works Kure Branch Works established
Kure Branch Works became independent from Hitachi Works
Totally independent from Hitachi Ltd.
1987
1995
2003
2005
2006
2011
Merged Capital1,235million
(Capital 1,852.5 million)
(Capital 2,637.5 million)
[Expansion on Production Locations]

[Expansion on Production Locations]
(Capital 3,000 million)

Share Holding Ratio amounted to
100% of Hitachi, Ltd.
(Capital 5,000 million)
1987
1987Akitsu
AkitsuWorks
Works
1989
Noumi
Works
1989 Noumi Works
1989
1989Philippines
Philippines(BHPI)
(BHPI)
1996
China
(BHDB)
1996 China (BHDB)
Babcock Borsig Power Systems (BBPS ) acquired

Hitachi Power Systems America (HPSA) established
Hitachi Power Europe (HPE) established
Main Products
Power Boilers
HRSG
Industrial Boiler
Incinerators
Integrated &
Dedicated
Product Line-up for
Power and Industrial
Plant
FGD
SCR
Industrial Plants
Nuclear Power
Office & Works in Japan

Head office
Kure First Works

Kure, Hiroshima, Japan
Design and manufacturing of boilers
Kure Second Works

Kure, Hiroshima, Japan
Manufacturing of nuclear power
related products
Location: Akihabara
UDX Building, Tokyo
Japan
Noumi Works
Edajima, Hiroshima, Japan
Manufacturing of heat recovery
steam generators and other
products
Akitsu Works
Higashihiroshima, Hiroshima, Japan
Manufacturing of catalysts
HITACHI Global Network for Boiler and AQCS

As a core company of the HITACHI / Power & Industrial group,
we provide boiler and AQCS services globally
Global Network
Works Worldwide
Hitachi Power Europe GmbH (HPE)

Duisburg, Germany
Engineering, procurement, manufacturing and
sales of boilers, AQCS and related equipment.
Hitachi Power Systems America, Ltd.

(HPSA)
Basking Ridge, NJ, USA
Engineering, procurement and sales of
boilers and Air Quality Control System
(AQCS)
10
FGD retrofits HITACHI formation

Customer
EPC contract
Joint & Several

Consortium
Hitachi Power Europe
Local partner
Sub-Contractors
11
FGD retrofits
complete solution on cooperation with Knauf Gips
Customer
EPC
contract
Off-take contract
Cooperation
Knauf Gips KG
Babcock Hitachi K.K.

Hitachi Power Europe GmbH
Sub-Contractors
12
Knauf Reference Example

Gypsum wall board plant near the power station
power
station
FGD Gypsum
store
Gypsum Wall
Board plant
13
Status of emission standards in Europe
14
Japanese regulation of flue gas treatment
80 NOx:70ppm (144mg/Nm)
SO250ppm (142mg/Nm)
NOx50ppm (103mg/Nm)
60
40
20
NOx:35ppm (71mg/Nm)
SO2:25 ppm (71mg/Nm)
3 3N
Dust 20mg/m
Dust:20mg/Nm
3
Dust:10mg/Nm
10mg/m3N
Dust:5 mg/Nm3
Dust Conc. (mg/Nm)

SO2 Conc. (ppm)
100
SO2:100ppm (285mg/Nm)
0
1980
1990
1995
2000
2005
2010
(Year)
15
Air Quality Control System (AQCS)

AQCS
Air Quality Control Systems
Boiler
DeNOx(SCR)
FGD
Stacks
ESP
Boilers
DeNOx
(SCR)
Stack
FGD : Flue Gas

Desulfurization
ESP
A/H
FGD
Hitachi
Hitachiisisone
oneof
of
few
fewAQCS
AQCSSupplier
Supplier
for
fortotal
totalsystem
system
(Layout for 1000MW coal fired plant in Japan)

16
Measures for SO2 Reduction

Activated carbon method
Dry Process
Fly ash method

Activated coke method
Spray Dryer Absorber (SDA)
Semi-Dry Process
Wet Process
Circulating Dry Scrubber (CDS)

Limestone Injection into Furnace and Flue
Gas Humidification
Limestone-Gypsum method
Magnesium Hydroxide -Gypsum method
Sea water method
17
FGD Process: Wet Limestone-Gypsum Process

Technical Response to Emission regulations
Forced oxidation limestone gypsum process as almost standard technology
(after technological and economical comparison)
Reasons for the wide application of Wet Limestone-Gypsum Process
1) Limestone* is
Cheapest Absorbent
Abundant in nature
Easy Handling
2) Gypsum is
Useful for Cement Additives

Useful for Wallboard Materials
Easy Storing
Easy Handling
3) The System is
Simple
Easy to Operate
High Reliability
High efficiency
Performance optimisation and cost reduction results in highly standardised absorber

* also quick lime technology available (Walsum Power Plant - Branntkalk)
18
2. Babcock-Hitachis WFGD Technology
19
Development of Hitachi WFGD System

1962
1970
1980
1975
Initial Stage
1985
Improvement of Reliability
Reduction of Utility
1990
Meeting Middle Load Ope.
2000
2005
2010
2015
Targeting Low Utility and Cost
Simplification of the System
SPRAY TOWER
PERFORATED TRAY TOWER
1995
ADVANCED SPRAY TOWER
LIMESTONE GYPSUM FGD SYSTEM
PERFORATED
TRAY TOWER
R&D / PILOT
COMMERCIAL PLANT ( Total 15, - COAL 3, OIL 12 )
SPRAY TOWER
COMMERCIAL PLANT ( Total 9, - COAL 4, OIL 3, COM 1, PET COKE 1 )

COMMERCIAL PLANT
( Total 52, - COAL 41, Lignite 3 ORIMULSION 2, OIL 2, PET COKE 2, R.O. 2 )
TAMASHIMA #3 500MW
MATSUSHIMA #2 500MW
TRAY TOWER
SPRAY TOWER
MATSUURA #1 1,000MW
TACHIBANAWAN #2 1,050MW
20
Wide Application of BHK WFGD System

COAL / LIGNITE
OIL
BHK FGD SYSTEM

RESIDUAL OIL
FUEL
BHK'S EXPERIENCE
1.
2.
3.
4.
5.
6.
OIL
COAL
COM
ORIMULSION
RESIDUE OIL
PET.COKE
P. C.
ORIMULSION
INLET SO2 CONCENTRATION (ppm)

1000
2000
3000
4000
5000
Applied many kinds of fuel

Experience of high sulfur fuel
BHK FGD can be applied to

any kinds of fuel and
various sulfur containing fuel
21
Principle and System Flow of BHK Wet FGD System

LIMESTONE MILL
LIMESTONE
STACK
ESP
LIMESTONE PREPARATION SYSTEM
FAN
BOILER
GAS-GAS HEATER
GYPSUM
DEWATERING
WASTE
WATER
AIR
ABSORBER
GYPSUM
ABSORPTION SYSTEM
GYPSUM RECOVERY SYSTEM
CHEMICAL PRINCIPLE: SO2 Absorption and Oxidation
SO2+2H2O+CaCO3 (LIMESTONE) + 1/2O2 CaSO42H2O(GYPSUM)+CO2

22
Absorption system
LIMESTONE MILL
LIMESTONE
STACK
ESP
FAN
BOILER
GAS-GAS HEATER
GYPSUM
DEWATERING
WASTE
WATER
AIR
ABSORBER
GYPSUM
ABSORPTION SYSTEM

23
Principle of BHK Advanced WFGD System

(Chemical Reaction in Absorber)
SPRAY
NOZZLE
GAS FILM
SLURRY
Pso2
DROPLET
LIQUID
FILM
Xso2
ABSORPTION
AREA
GAS
DROPLET
FLUE GASSO2
SO2+2H2O+CaCO3+1/2O2CaSO42H2O+CO2
CLEAN GAS
TANK AREA
ABSORPTION
AREA
AIR ;
FLUE GAS
(GYPSUM)
(LIMESTONE)
AIR
TANK AREA
CHEMICAL
REACTION
SO2 Absorption
and Oxidation
SO2+2H2O+CaCO3 (LIMESTONE) + 1/2O2
CaSO42H2O(GYPSUM)+CO2
24
Outline of Babcock Hitachis Absorber

<Spray Header>
<Oxidation Agitator>
<Spray Nozzles>
<Air Dispersion>
25
Absorber Design
Absorber Outlet
(horizontal or vertical)
Mist Eliminator
(2 3 stages, depending
from allowable drop content)
Absorption Area
SO2 & Dust Removal
Absorber
Inlet
Spray Levels
(number of levels depending on sulphur in fuel,
if desired with space for retrofit of spare level)
Spray Nozzles
(up and/or down spray nozzles)
Absorber Sump
Oxidation
Dissolution of
Limestone
Crystal growth
Absorber sump
(with agitator for mixing
and oxidation air injection)
26
Absorber Material Rubber Lining Application

European Solution: Rubber Lined Absorber
Spec. A Rubber lined 2 x 6 mm

Spec. B Rubber lined 1 x 6 mm
Spec. C Alloy plated
Lifetime of more than 50.000 hours,

Maintenance and repair of coating by rubber lining specialist company only !
27
Absorber Material Flake Lining Application

Inspection After
3 Years Operation
Wear Resistant FRL

or Metal lined
Heat Resistant FRL
or Metal lined
Heat Resistant FRL
Spark test:
Inspection of lining
Acid Resistant FRL
Top coat
2nd layer
1st layer
Primer
28
Limestone Slurry preparation system

LIMESTONE MILL
LIMESTONE
STACK
ESP
LIMESTONE SLURRY
PREPARATION SYSTEM
FAN
BOILER
GAS-GAS HEATER
GYPSUM
DEWATERING
WASTE
WATER
AIR
ABSORBER
GYPSUM
ABSORPTION SYSTEM

29
Flow Diagram of
Limestone Slurry Preparation System
Main Process
Limestone
Water
H/C
Classifier
Silo
Grinding
/ Dilution
Water Supply
W
W
W
Limestone
Feeder
Distribution
System
W
High
W
Ball
Mill
Low
M
Limestone
Slurry Tank
Slurry Pump
Mill Tank
M
M
30
Limestone Preparation - Wet Ball Mill

- Quarry Ground Limestone or On-Site Mill
- Horizontal Ball Mill or Tower Mill
- 95% - 325 Mesh (44 m)
Horizontal
Ball Mill
- 30% Solids
H2SO4 consumption
(= Limestone Reactivity)
Limestone Activity Test

Photo Horizontal Ball Mill
Standard
<Before Project Start >
Evaluation of Limestone activity
Reliable
Design
Time
31
Gypsum Recovery System

LIMESTONE MILL
LIMESTONE
STACK
ESP
FAN
BOILER
GAS-GAS HEATER
GYPSUM
DEWATERING
WASTE
WATER
AIR
ABSORBER
GYPSUM
ABSORPTION SYSTEM

32

- Belt Filter Application
Overflow
Absorber Slurry
Hydro-Cyclone
Horizontal Belt Filter
By product
Gypsum
Water for
recycling
To Absorber
Filtrate Receiver
Vacuum Pump
33

- Belt Filter Application
Vacuum Belt Filter
Hydrocyclone
Slurry feed
Direction
Byproduct Gypsum
Vacuum
34
Typical Requirement of Gypsum Usage
BY-PRODUCT GYPSUM QUALITY
ITEM
ACTUAL
VALUE
CaSO4 2H2O
GENERAL REQUIREMENT
IN JAPAN
FOR
CEMENT
FOR WALL
BOARD
98.8 %
> 90 %
> 95 %
CaSO3 1/2H2O
< 0.05 %
< 0. 25 %
CaO3
0.32 %
Na+
0.001 %
0. 03 %
pH
6.8
5~8
PHOTO OF BYPRODUCT GYPSUM CRYSTAL
35
Requirement of Gypsum Quality in Europe

BY-PRODUCT GYPSUM QUALITY
ITEM
EURO GYPSUM
Criteria
H2O
< 10%
CaSO4 2H2O
> 95%
MgO
< 0.10
Na2O
< 0.06
Cl
< 0.01
CaSO3 1/2H2O
< 0.50 %
pH
5-9
Color
White
Odour
Neutral
Toxicity
Non-toxic
VGB-M 701e:
EURO GYPSUM: Quality Criteria and analysis methods
36
FGD Design Consideration for Lignite Coal
Large Flue Gas Volume

High SO2 Content
High Removal Efficiency
High Fly Ash Loading

High Inlet Gas Temperature
High Inlet Moisture
High Absorber Slurry

Temperature
*1 Gas Flow Rate shall be confirmed.
37
BHK Unique FGD Technology:

Wet Stack Solution
Wet
Wet stack
stack on
on top
top of
of Absorber
Absorber
FRP
Wet Stack
Absorber
Stand
Stand alone
alone Wet
Wet stack
stack
Wet Stack
Absorber
Features of
Wet Stack on top of Absorber
(1) Small-footprint
(2) Isolated from Absorber
Supported by Steel structure and
no load to absorber shell
38
FGD Waste Water Treatment Flowchart

(Example in Europe)
SS, Heavy Metals Removal
COAGULANT
Ca(OH)2
Raw
FGD
Waste
Water
Neutralization
Tank 1
FeCl3
TMT-15
Neutralization
Tank 2
Flocculation
Tank
Waste Product
Lamella
Clarifier
Cooling
water
Treated Waste
Water Tank
Discharge
to River
Filter Press
HCl
Polymer
Sludge Storage
Tank
39
3. Experiences
40
HITACHIs FGD Experiences in Europe
(800MW x 2)
(750MW x 1)
(800MW x 4)
(800MW x 1)
(556MW x 1)
(220MW x 1)
41
Reference Plant Industry Recognition

Ameren Services (USA) / Coffeen Power Plant / No. 1, 2
POWERs 2011 Plant of the Year
- Power Magazine (Oct 2011)
Project of the Year Award

- Power Gen International 2011 in Las Vegas, USA
42
4. Research & Development
43
R&D Facilities
Boiler-AQCS
Boiler-AQCS Pilot
Pilot Test
Test Facility
Facility
Desulfurization
Desulfurization Test
Test Facility
Facility
FF
Absorber A
WFGD
DESP
Flue gas
treatment facility
Absorber B
4 Absorbers and 1 Reaction Tank Test Facilities

e.g.
Absorber A
-Gas flow: 22,000m3N/h
-SO2 conc.: 500 ppm
-Abs. dia.: 680mm
WESP
Burner
Combustion
facility
Coal Feed Rate 100~150 kg/h

Gas Flow Rate 1,000~1500 m3N/h
Abs. dia:
480 mm
WESP GGH
Coal
Absorber B
-Gas flow: 250m3N/h
-SO2 conc.: 20,000ppm
-Abs. dia.: 160mm
SCR
G/C
GGH
CEM
DESP
BUF
IDF
WFGD
SCR
Pump
FF
44
Computational Flow Model

< Model Consideration >
- Spray Droplets
- Kinetic Momentum (Droplet/Gas)
Track of Spray Droplet

Gas Distribution
Flow Model Results

Confirmation of Optimized Absorber

internal arrangements by Flow Model to
prevent the gas short-pass.
45
5. Conclusions
46
Special Features of BHK FGD System

Total Engineering Capability with Boiler Plant Engineering
corresponding to various kinds of fuel
Best-Mix of Japanese & European State of the Art Technologies

Excellent Advanced Spray Tower Absorber Design featuring;
a) Higher SO2 Removal Efficiency & Dust Removal Efficiency
b) Lower Gas Pressure Drop Less Boost-Up Fan Capacity
c) Excellent Liquid/Gas Contact Less Recirc. Pump Capacity
d) Higher Quality of By-Product Gypsum
Re-Use for Cement Additive and/or Wall Board Material
Full Support by R&D Facility

Proven FGD Technology and High Reliability
47
6. SCR Process
48
SCR Process
SCR ; SELECTIVE CATALYTIC REDUCTION
REACTION FORMULA
4NO + 4NH3 + O2 4N2 + 6H2O

NO + NO2 + 2NH3 2N2 + 3H2O
6NO2 + 8NH3 7N2 + 12H2O
NH3
NOx
NOx
CATALYST
NH3
NOx
NH3
NOx
NOx
NH3
H 2O
N2
H 2O
N2
H 2O
CLEAN
GAS
49
Scheme of SCR System

NH3 injection
SCR Reactor
ECO
EP
DeSOx
BOILER
STACK
Catalyst
FDF
NOx ANALYZER
NH3 STORAGE TANK
BOILER
LOAD
SIGNAL
MIXER
FIC
EVAPORATOR
ACCUMULATOR
NH3 Storage & Supply

Reactor Design
51
SCR Retrofit Example

SCR reactor
APH
ESP
APH
SCR Retrofit to Existing

boiler
ESP
52
SCR Reactor
NH3 INJECTION GRID
INLET DUCT
MAIN MONORAIL
CASING
HOIST
CATALYST BLOCK
OUTLET DUCT
SUPPORTING
STRUCTURE
53
Plate Type Catalyst

CATALYST ELEMENT
CATALYST UNIT
CATALYST BLOCK
54
55

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Introduction of Babcock-Hitachi K.K.

Wet Flue Gas Desulphurization System

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Babcock-Hitachi in HITACH Group

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Power Systems Company of HITACHI

CO2 Capture Solution

GTCC, Preventive Maintenance, etc.

Wind Power Sys. Solar Power Sys.

Hydro Power Sys.

Preventive Maintenance, Fuel Cycle, etc.

Nuclear Power Business

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Outline of Babcock-Hitachi K.K.

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Hitachi Works Boiler Manufacturing

[Expansion on Production Locations]

(Capital 3,000 million)

(Capital 5,000 million)

Babcock Borsig Power Systems (BBPS ) acquired

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Office & Works in Japan

Kure First Works

Kure Second Works

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

HITACHI Global Network for Boiler and AQCS

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Hitachi Power Europe GmbH (HPE)

Hitachi Power Systems America, Ltd.

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

FGD retrofits HITACHI formation

Joint & Several

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

complete solution on cooperation with Knauf Gips

Babcock Hitachi K.K.

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Knauf Reference Example

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Status of emission standards in Europe

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Japanese regulation of flue gas treatment

Dust Conc. (mg/Nm)

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Air Quality Control System (AQCS)

FGD : Flue Gas

(Layout for 1000MW coal fired plant in Japan)

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Measures for SO2 Reduction

Fly ash method

Circulating Dry Scrubber (CDS)

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

FGD Process: Wet Limestone-Gypsum Process

Useful for Cement Additives

Performance optimisation and cost reduction results in highly standardised absorber

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

2. Babcock-Hitachis WFGD Technology

All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Development of Hitachi WFGD System

Meeting Middle Load Ope.

Targeting Low Utility and Cost

Simplification of the System