Environmental Control System

for Thermal Power Plants

DESOx and DENOx

Working
today
for
tomorrow's
world

The future of our planet and the lives we lead is at stake. To progress, we must
develop new and better ways to satisfy society's growing energy needs. Yet, at
the same time, we must guarantee safety-improving our methods, while
protecting the environment.
At Babcock-Hitachi K. K., we are a world leader in energy-related technologies
and environmental systems. Our power and industrial plant boilers improve plant
performance, while our flue gas desulfurization systems (DESOx) and NOx removal
systems (DENOx) protect the environment. Our technologies lend new found
quality and security to vital industries. And we are constantly updating our
research to better meet the needs of our clients.

1963 1970
R&D

1972

1974

1976

1978

1980

1982

1984

1986

1990

1995

2000

2005

2010

Tray Tower
R&D Spray Tower
R&D Advanced Spray Tower

DESOx

Commercialization
R&D Catalyst Composition
Catalyst Configuration Pellet type
R&D

Catalyst Configuration Plate type

Commercialization

DENOx

Flue Gas Desulfurization Systems

In the early 1960s, before other commercial enterprises got on
the bandwagon, Babcock-Hitachi K.K. (BHK) began developing
Flue Gas Desulfurization systems (FGD). Our first commercial
system went into operation in April, 1974. Then, as a result of
continuous technical improvements, our first 1,050 MW plant
started up in 2000. FGD system technology of BHK is contributing
to the prevention of air pollution not only in Japan but also in
European countries, the USA and Asian countries.

Electric Power Development Co., Ltd. (Japan)

Tachibanawan Power Station, No. 2 Unit
The largest DESOx plant in Japan
Boiler Fuel:

Coal

Size:

1,050 MW

Gas Capacity:

3,280,000 Nm3/h

Conc. of Inlet SO2:

822 ppm

SO2 Removal Efficiency:

94% or more

Absorber Type:

Advanced Spray Tower

(In-Situ Oxidation)

Gas Reheating System:

Non-Leakage Gas-Gas Heater

Placed in Operation:

December, 2000

Principle & System Flow

BHKs FGD system uses the latest type of spray tower (advanced spray
tower) combining three important functions; oxidation, both SO2 and
particulate removal. This advanced system requires less equipment,
less space and fewer utilities than its predecessors.

DESOx Flow Diagram

Bypass Damper
Limestone
ESP

Fan

Stack

Boiler

Limestone Silo

Gas--Gas Heater

Process Input

Mist
Eliminator

SO2
Flow

Gypsum
Dewatering

pH

Oxidation Blower

Control Signal

Absorber

Absorber
Recirculating
Pump

Gypsum

Chemical Principle of FGD

SO2 Absorption and Oxidation
SO2+2H2O+CaCO3 (Limestone) +1/2O2

CaSO4 2H2O (Gypsum) +CO2

Summary of Latest Technology Improvement

The following new design concepts are adopted in our advanced FGD systems:
1. Higher gas velocity
2. Decrease of spray stages
3. Higher slurry concentration
4. Effective in-situ forced oxidation

2. Decrease of Spray Stages

1. Higher Gas Velocity

Increase of
SO2 Removal
Efficiency

Droplet

Gas Velocity: < 3m/s

Gas Velocity: = 3 5m/s

SO2 Removal Efficiency

Gas

Slurry

Pressure Drop

Liquid/Gas Ratio = Constant

Gas Velocity

Gas

3. Higher Slurry Concentration

Slurry

4. Effective In-Situ Forced Oxidation

Limestone
Gypsum

High Concentration

SO2 Removal Efficiency

Low Concentration

Tiny Bubbles
Less Air Required
Slurry Concentration

Air

Air

No Plugging

In addition to the conventional vertical absorber, we have developed a new absorber

using the latest technical improvement to meet customers various requirements.
This new absorber has economical features:
1. Less flue gas duct realized using low absorber height
2. Less supporting structure of mist eliminator realized using low absorber height
3. Pressure drop through the absorber is equivalent to the conventional FGD

Compact FGD System

This system was developed as an economical alternative.
Absorber can be installed or retrofitted easily between the flue gas ducts.
Its construction is simple achieving SO2 removal efficiency up to 90%.

Flue Gas
Inlet

Mist Eliminator

Spray Headers

Flue Gas
Outlet

Return Flow Type

Flue Gas
Inlet

Flue Gas
Outlet

Return flow type was developed as an alternative

to the conventional absorber.
The SO2 removal efficiency is higher than that of a
conventional vertical absorber.
7

Non-Leakage Gas-Gas Heater

This equipment recovers heat from the flue gas and reheats
the treated flue gas for FGD plants without any flue gas
leakage. To comply with increasingly more stringent emission
regulations, this type of gas-gas heater is indispensable.

Untreated Gas
Heat Recovery Section

Reheat Section

Treated Gas

Typical Configuration

Heat Transfer
Medium Heater

Auxiliary Steam

Untreated Gas

Treated
Gas

Heat Recovery Section

Reheat Section

Heat Transfer
Medium Recirculation Pump

Typical Flow Sheet

Heat Transfer
Medium Tank

New Flue Gas Treatment System with Ultra-low Dust Emission

BHK has developed a new flue gas treatment system consisting of ESP, FGD plant and gas-gas heater,
which realizes effective treatment of flue gas so that the system can keep dust emissions well within
stringent regulations.
This new flue gas treatment system of BHK has already been patented in Japan.

New Flue Gas Treatment System

Boiler
DENOx
A/H

GGH

DESOx

ESP

(Heat Recovery)

GGH
(Reheat)

IDF

Stack

90 100C

Conventional Flue Gas Treatment System

Boiler
DENOx
A/H

ESP

GGH
IDF

(Heat Recovery)

DESOx

GGH
(Reheat)

Stack

130 140C

The new system has the following features:

1. Lower ESP capacity
2. Increased gypsum purity
3. Lower stack emissions
4. Lower ID-fan capacity and power consumption

Applications

Electric Power Development Co., Ltd. (Japan)

Matsuura Power Station, No. 1 Unit
First 1,000 MW class application in Japan
Boiler Fuel:

Coal

Size:

1,000 MW

Gas Capacity:

3,268,000 Nm3/h

Conc. of Inlet SO2:

992 ppm

SO2 Removal Efficiency:

90% or more

Absorber Type:

Advanced Spray Tower (In-Situ Oxidation)

Absorption System:

Dust Mixing System

Gas Reheating System:

Gas-Gas Heater

Placed in Operation:

June, 1990

Soma Kyodo Power Co., Ltd. (Japan)

Shinchi Power Station, No. 1 Unit
Boiler Fuel:

Coal

Size:

1,000 MW

Gas Capacity:

3,040,400 Nm3/h

Conc. of Inlet SO2:

920 ppm

SO2 Removal Efficiency:

90% or more

Absorber Type:

Advanced Spray Tower

Absorption System:

Dust Separation System

Gas Reheating System:

Non-Leak Gas-Gas Heater (Heat Pipe)

Placed in Operation:

June, 1994

Elektrownia Kozienice S.A. (Poland)

Kozienice Power Station, Either No. 9 or 10 Unit

10

Boiler Fuel:

Hard Coal

Size:

500 MW

Gas Capacity:

2,300,000 Nm3/h

Conc. of Inlet SO2:

1,103 ppm

SO2 Removal Efficiency:

93% or more

Absorber Type:

Advanced Spray Tower (In-Situ Oxidation)

Absorption System:

Dust Mixing System

Gas Reheating System:

Gas-Gas Heater

Placed in Operation:

June, 2001

Kansai Electric Power Co., Inc. (Japan)

Miyazu Power Station, No. 1 and 2 Units
Boiler Fuel:

Heavy Oil

Size:

375 MW

Gas Capacity:

1,120,000 Nm3/h

Conc. of Inlet SO2:

580 ppm

SO2 Removal Efficiency:

90% or more

Absorber Type:

Spray Tower

Absorption System:

Dust Separation System

Gas Reheating System:

Gas-Gas Heater

Placed in Operation:

August, 1989 (No. 1 Unit)

December, 1989 (No. 2 Unit)

Hokkaido Electric Power Co., Inc. (Japan)

Shiriuchi Power Station, No. 2 Unit
Boiler Fuel:

Orimulsion

Size:

350MW

Gas Capacity:

1,071,000 Nm3/h

Conc. of Inlet SO2:

2,465 ppm

SO2 Removal Efficiency:

94% or more

Absorber Type:

Advanced Spray Tower

Absorption System:

Dust Mixing System

Gas Reheating System:

Gas-Gas Heater

Placed in Operation:

September, 1997

Tokyo Electric Power Co., Inc. (Japan)

Yokosuka Power Station, No. 2 Unit
DESOx plant was retrofitted following the conversion of fuel from oil to COM.
Boiler Fuel:

COM (Cole-oil mixture)

Size:

265 MW

Gas Capacity:

925,000 Nm3/h

Conc. of Inlet SO2:

780 ppm

SO2 Removal Efficiency:

90% or more

Absorber Type:

Spray Tower

Absorption System:

Dust Separation System

Gas Reheating System:

Gas-Gas Heater (Heat Pipe)

Placed in Operation:

May, 1985
11

NOx Removal Systems

In the 1960s, when air pollution emerged as a major global
concern, BHK started research and development for
reducing of NOx emissions from power plants. BHK first
developed a pellet type DENOx catalyst.
Based upon this original catalyst, BHK developed a lowpressure drop plate type catalyst, which is presently one
of our major products.
Contributing to global environmental preservation, the
DENOx catalysts have been adopted throughout the world,
North America, Europe and Asia, as well as in Japan, and
have maintained an excellent reputation for high
performance.

Electric Power Development Co., Ltd. (Japan)

Matsuura Power Station, No. 1 Unit
Boiler Fuel:

Coal

Size:

1,000 MW

Gas Capacity:

3,029,000 Nm3/h

Conc. Of Inlet NOx:

250 ppm

NOx Removal Efficiency:

80% or more

Placed in Operation:

June, 1990

AES Somerset Station, No. 1 Unit (USA)

Boiler Fuel:

12

Coal

Size:

675 MW

Gas Capacity:

2,241,230 Nm3/h

Conc. Of Inlet NOx:

340 ppm

NOx Removal Efficiency:

90% or more

Placed in Operation:

July, 1999

Basic Principle of NOx Removal

The basic principle of DENOx is simple. Ammonia
is injected into the flue gas and NOx is decomposed
into N 2 and H 2 O vapor. The DENOx catalyst
efficiently facilitates ammonia and NOx reactions.
The process forms no harmful by-products.
Also plants using the DENOx catalyst are
easy to maintain and are capable
of stable operation.

H2O
N2
N2
H2O

H2O

N2

H2O
N2

NOx

NH3
NH3

NH3
NOx
NH3
NOx

Gas
NOx
NOx

NOx
NOx

Chemical Reactions of DENOx

4NO + 4NH3 + O2
4N2 + 6H2O
6NO2 + 8NH3
7N2 + 12H2O

Applications of the DENOx System

Gas

BHK DENOx catalyst has been applied to many types of

boilers, HRSGs and heaters that use various fuels. In
particular, BHK DENOx catalyst has gained a superb
reputation in the field of coal-fired boilers. Very low
plugging potential and extremely high erosion resistance
are some of the reasons for this reputation.
An additional unique feature of the BHK catalyst is the
adjustable plate size that enables the product to fit any
flue size.

Ammonia

Conventional Boiler Application

Air
13

Catalyst Manufacturing
All of BHK DENOx catalysts are produced in its
own manufacturing facility, currently in Akitsu,
Japan.
Over the past 40 years, the manufacturing has
been continuously improved as a result of
ongoing research into the product to increase
its effectiveness.
The present high quality, high performance and
highly competitive DENOx catalyst is the
culmination of four (4) decades of experience
and continuous development.

High Erosion Resistance

The center metal of BHK's plate type DENOx
catalyst contributes to the catalyst's high erosion
resistance against the dust in gases. The
substrate does not wear away allowing gas
straightening to stop erosion. Homogeneous
catalysts continuously wear away.

Gas

Gas

Dust

Dust

Catalyst
Center Metal
Plate

Plate Type Catalyst

Catalyst

Solid Material Catalyst

Compact Reactor
with Multi-Catalyst Stacking
BHKs plate type DENOx catalyst allows multilayer stacking, which makes the reactor more
compact at the same catalyst volume.

Space for Added Catalyst

Reactor

Catalyst Block
(1-stage Model)
Compact Reactor Using
Stacked Plate Type Catalyst

14

(5-stage Model)
Multistage Reactor

Duct Size (Application in HRSG)

The table below compares the plate type catalyst with the honeycomb type catalyst.

Outlet Duct
Reactor
Inlet Duct

Outlet Duct
Reactor
Inlet Duct

Gas
Gas

Honeycomb Type Catalyst

Plate Type Catalyst

Features of plate type catalyst compared with honeycomb type

(based on BHKs own evaluation)
Pressure Loss:
Gas Flow Distribution:
Design, Manufacture and Installation:
Reactor (width):

Lower
Superior
Simple
More Compact

Honeycomb type catalyst needs larger duct dimensions due to higher pressure loss.

Photos of Plate-Type Catalyst

The photos show the gas entrance edges of a plate
type catalyst installed in a high dust concentration
of a coal-fired boiler. Even after 50,000 hours of
operation, the catalyst shows negligible erosion
and, although no soot blowing equipment is
employed, the catalyst layer is clean.

Before operation

After 50,000 hours operation

15

Our Record Speaks for Itself

Kraftwerk Mehrum (Germany)

Mehrum Power Station, No. 3 Unit
Boiler Fuel:

Coal

Size:

700 MW

Gas Capacity:

2,240,000 Nm3/h

Conc. of Inlet NOx:

390 ppm (6% O2)

NOx Removal Efficiency:

75% or more

Placed in Operation:

February, 1989

Tokyo Electric Power Co., Inc. (Japan)

Sodegaura GT Power Station, No. 1 Unit
Gas Turbine Type:

GE Frame 9 E

Fuel:

LNG

Size:

127 MW

Gas Capacity:

1,226,000 Nm3/h

Conc. of Inlet NOx:

50 ppm (16% O2)

NOx Removal Efficiency:

60% or more

Placed in Operation:

March, 1993

Korea Electric Power Cooperation (Korea)

Namcheju Power Station, No. 3 Unit
Diesel Engine Fuel:

16

Heavy Oil

Size:

10 MW

Gas Capacity:

72,700 Nm3/h

Conc. of Inlet NOx:

1,400 ppm (13% O2)

NOx Removal Efficiency:

65% or more

Placed in Operation:

November, 1999

The Los Angeles Department of Water & Power (USA)

Haynes Power Station, No. 1 Unit
Boiler Fuel:

Natural Gas

Size:

230 MW

Gas Capacity:

739,600 Nm3/h

Conc. of Inlet NOx:

100 ppm (3% O2)

NOx Removal Efficiency:

92% or more

Placed in Operation:

June, 1993

Watson Cogeneration Company (USA)

No. 1, 2, 3 and 4 Units
Gas Turbine Type:

GE Frame 7

Fuel:

Natural Gas

Size:

80 MW

Gas Capacity:

830,000 Nm3/h

Conc. of Inlet NOx:

45 ppm (15% O2)

NOx Removal Efficiency:

90% or more

Placed in Operation:

December, 1987

Tokyo Electric Power Co., Inc. (Japan)

Futtsu Power Station, No. 3 Unit
Gas Turbine Type:

GE Frame 9 FA++

Fuel:

LNG

Size:

380 MW

Gas Capacity:

1,870,000 Nm3/h

Conc. of Inlet NOx:

45 ppm (16% O2)

NOx Removal Efficiency:

90%

Placed in Operation:

July, 2001
17

Kure Division of Babcock-Hitachi K.K.

Operation Start: November, 1959
Facilities:
Manufacturing of boiler plants, desulfurization
plants (DESOx), nuclear power plant equipment,
industrial plants and incineration facilities

ISO9001
Established quality program and succeeded to get the initial certificate
of approval on July 12, 1994.

Akitsu Works of Babcock-Hitachi K.K.

Operation Start: March, 1987
Facility:
Continuous automatic manufacturing
process of catalyst
Site Area: 127,000 m2

Sales and Service Network

Hitachi Worldwide Network

Hitachi Sales and Service Companies
and Liaison Office
18

See : www.hitachi.com/products/power/envequip/
www.bhk.co.jp

Babcock-Hitachi K.K.
4-1 Hamamatsucho 2-chome, Minato-ku, Tokyo 105-6107, Japan
Tel : +81-3-5400-2412
Fax: +81-3-5400-2461
www.bhk.co.jp
Printed in Japan 0902