Carmeuse FGD experience in USA

Bob Roden
Director FGT Markets

Customers

Currently supplying 20,000 MWs to FGD

Ranging in size from 50 to 1,400 MWs
Providing 4 million tons of reagent per year
Lime and Limestone
Carmeuse is in a unique position to observe both
start-up and long term operation of FGD systems
What have we seen work successfully?

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What Goes on in the FGD System

First SO2 Dissolved in Liquid

Sulfur Dioxide Dissolves in Water
SO2 (g) + H2O
HSO3- + H+

Limestone Neutralizes Acid in the Liquid

Liquid drop to Reaction Tanks

Sulfite goes to Sulfate (Oxidation)

HSO3-1 (l) + 0.5 O2

SO4-2 (l) + H+

Oxidation - Air blown into absorber with oxidation air

compressors, dispersed by the agitators

Enhances Speed of Second Reaction

SO4 reacts with limestone forming gypsum

SO4-2+Ca+2+2H2O
CaSO4 .2H2O

You are operating a CHEMICAL plant

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Staffing requirements

Process owner
Lab personnel
Dedicated operators
Dedicated maintenance
Mechanics
Instrumentation

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Variables for System Control

Limestone Quality
Absorber Operating Variables
Dewatering Operating Variables

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Monitoring and Testing

Process Stream Testing

Limestone
Limestone Slurry
Absorber Bleed Slurry
Hydroclone Slurries
Gypsum

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Monitoring and Testing

Process Testing
Limestone
CaCO3, MgCO3 , Inerts, Silica
Limestone Slurry
Particle Size and Limestone Purity
Absorber Slurry
pH
Oxidation (Calcium Sulfate vs. Calcium Sulfite)
Inerts
Chloride
Density
Gypsum particle Size

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Monitoring and Testing

Process Testing
Hydroclone Slurries
Particle Size
Gypsum Purity
Inerts
Density
Gypsum Final Product
Particle Size
Purity
Moisture
Chloride
Inerts

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Variables Effecting FGD Goals

Limestone Quality

Limestone Quality
Purity (Calcium Carbonate) 95%
Better the limestone, less usage, less waste, better SO2 reaction
If it is not CO3 , it is a waste product
Every % Inert material results in cost

Iron (Iron Oxide) less than 0.25%

Adversely effects gypsum production above 0.8%
As Iron gets higher, more fine gypsum particles are produced

GYPSUM SIZE CURVE EXCESS IRON

TYPICAL GYPSUM PARTICLE SIZE CURVE

40%
35%
30%
25%
20%
15%
10%
5%
0%

50%
40%
30%
20%
10%
0%

5 microns

40microns

Particle Size

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80 microns
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5 microns

40microns

Particle Size

80 microns

Variables Effecting FGD Goals

Limestone Quality

Limestone Quality (Continued)

Hardness
Got to be able to grind material 14 on index
Harder material more horse power to grind
Hard material will reduce Ball Mill Capacity

Silica
Silica Limit on Stone should be at 2%
Higher Silica, More wear and tear
Ball Mills, pumps and valves

- Ball Mill Liners

- Recycle and Process Pumps
- Limestone Control Valves

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Variables Effecting FGD Goals

Limestone Quality

Limestone Quality (Continued)

How to Control
Monitor Supplier
Vendor Data, Quarry Info (know before it gets in their shipping pile)
Do your own testing

Equipment Surveillance
Equipment Inspection

- Mills, Mill Product Pumps, Hydroclones & Control valves best

indicators
Ensure Proper Mill Operation
Maintaining Mill operation to grind material to sizing and density

- Mill fineness test Want limestone less than 325 mesh (44m)
- Looking for surface area, smaller particle, higher surface area
To avoid such problems consider outsourcing milling step to a strategic
partner
May be the key to get guaranteed reagent availability at best price with lowest

operating concerns

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Variables Effecting FGD

Absorber Operating Parameters for Control

Everything occurs in the Absorber, actions downstream are
difficult to make to impact corrective action
pH/Reagent Control
Density
Oxidation
Recycle Rate/Retention Time

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Variables Effecting FGD

Absorber

Operating Parameters

pH and Reagent Control

Reagent Control is important for two reasons
Required to supply enough limestone to neutralize acids (HCl,SO2)
Provide appropriate pH for optimum Oxidation
Reagent Control Philosophy
Feed forward from SO2 Monitors provide main control
pH is the trim control

Each control Limestone Slurry Feed Control Valve

CaCO3 Required = SO2 flow * 100/64 * removal rate
Control valve set by reading flow (flow * density = lbs/hr of CaCO3 )

Adverse Effects from non conformance

Low pH
Not removing enough SO2
Increased Corrosion Potential

High pH poor oxidation and excess limestone in gypsum and scaling

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Variables Effecting FGD

Absorber

Operating Parameters

Density Control
Density should be controlled at 20% solids
Surface area (Particles) is required for site to precipitate gypsum
Low density will provide multiple issues

- Gypsum will form small particle as it precipitates instead of

precipitating on other gypsum particle, making them grow to
larger size
- Gypsum will find surface area if one is not provided
- Pumps, piping, tank walls, MEs

High density will cause slurry difficult to pump and potential pluggage of recycle

header nozzles and on the absorber tower tray

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Variables Effecting FGD

Absorber

Operating Parameters

Oxidation
You want all Sulfate in Tank no Sulfite
Force the reaction speed to increase
SO3 to SO4 does not occur quickly, must Force Oxidation

Force all gypsum to deposit in reaction tank onto other solids

Inhibits/Eliminates Re-Emission of Mercury

Oxidation Requirements
Correct pH Range
Enough Air
O2/S ration of 2.5/1 (By Design)
Higher Sulfur Coal More Air
Good distribution of air bubbles
Tank Level to provide head required for bubble retention

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22
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Variables Effecting FGD

Dewatering

Operating Parameters

Dewatering System
Vacuum Belt Operation
Correct Solids Density Provides Better Dewatering
Even Flow of Material Across the Vacuum Belt
Quality Wash Water Delivered evenly across filter
Vacuum Pumps and System Operating per design

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Variables Effecting FGD

Dewatering

Operating Parameters

Production of Specification Gypsum

Bad Actors in Gypsum Production
Inerts (Ash and Silica)
Ash from Boilers
Silica from Limestone

Small Particle Size Will not dewater

Too much energy into gypsum, breaking crystals
Poor overall Chemical control -Chlorides, pH

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 Questions?

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