Contract project-2004 With Ministry of Environment, Japan

Ministry of the Environment

Air Pollution Control Technology In Thermal Power Plants

March 2005

Overseas Environmental Cooperation Center, Japan

Air Pollution Control Technology in Thermal Power Plant

Committee Members
Chairman: Dr. K. Nishida, Researcher, Department of Urban and Environmental Engineering, Kyoto University (Retired) Member: Mr. S. Iwasaki, Director, Metocean Environment Inc. Dr. S. Fujii (P.E.), Takuma Co., Ltd. Mr. Y. Ogino (P.E.), Environment Technology L.P.C.

Prepared by
Dr. A. Hogetsu (P.E.), Research Commissioner, OECC

Hitachi Naka Thermal Power Station Tokyo Electric Power Co., Inc.
MW, Coal Fire

De-SOx

Generator Building, De-NOx, EP, De-SOx

1. Air Pollutions in Thermal Power Plant

1-1 Pollutants Emission Dust Hydrocarbons SOx, NOx, CO2 Trace Substances Particles

Dust

Oil N. Gas

Power Plant

Ash, Clinker, Heavy Metal

Disposal, Reuse

In-Plant Waste Treatment

Combustion Equipment

Coal

Exhaust Gas Treatment Facilities

Storage Facilities

1. Air Pollutions in Thermal Power Plant

1-2 Pollutants and Pollution Control in Coal Fire Power Plant

Pure Water Feed Unit Water

Turbine Generator

Steam Dust Coal Silo Boiler De-NOx

SOx NOx Dust T. Metals, etc Cd, Hg, Pb, Ni, As, F,

EP

De-SOx Stack

Dust Coal Unloading Vessel Fly Ash Collector Ash Pond

Gypsum Ash

1. Air Pollutions in Thermal Power Plant

1-3 Pollutants and Pollution Control in Oil Fire Power Plant

Pure Water Feed Unit Water Hydro Carbon Oil Tank

Turbine

Generator

SOx NOx Dust Trace Metal (V, Ni)

Steam

Boiler

De-NOx

EP

De-SOx Stack Gypsum

Tanker Ash

1. Air Pollutions in Thermal Power Plant

1- 4 Pollutants and Pollution Control in Gas Fire Power Plant

Flare Stack

Pure Water Feed Unit

Turbine

Generator

NOx

BOG (CH4)

Water

Steam

Fuel Tank LNG

Boiler

De-NOx Stack

BOG: Boil-off Gas

2. Measures against Fuel

2-1 Coal Fire Power Plant Dust collector surface compaction dust cover water spray windshield plate
Dust Dust water spray 6~12 % water, (surfactant) Dust Dust

Dust Control

windshield net
or

windbreak forest

dust v 4~5

or ey nv co

coal unloader relay section stacker reclaimer

2. Measures against Fuel

2-2 Oil and Gas Fuel Power Plants

Effect of fuel oil properties on exhaust gas quality

1. 2. 3. 4. Residual Carbon Soot, Dust Dust collection Nitrogen NO Denitrication Sulphur SO Desulphurization Ash Pressure drop, Heat transfer broke, Mechanical Wear, Corrosion Maintenance

Effect of fuel gas properties on exhaust gas quality

1. Impurity substancesNone 2. NitrogenNone NOx (thermal type) Denitrification 3. SulphurNone

3. Combustion Control
3-1-1 Coal Properties

Effect of Coal Properties on Pulverized Coal Combustion Ignitability & Combustibility optimum range effects in case of off-spec.
Fixed-C / volatile content Volatile content Ignitability Index Button Index (viscosity) 2.5~3.0 20 35 67 increase of non-burn loss unstable ignition hard ignition clogging, adhesion

Grindability
Proper size Dryness 50100m H2O 20 % 1,300 0.5 0.33 2% increase of non-burn loss lowering mill performance

Slagging
Ash Melting Temp. Ash Alkaline Ratio Fe2O3CaO Scoal slagging

Fouling Wear-out Nature

basic content; Na2O, K2O, Cl, CaO, S quart, Fe2O3,S

fouling on inner furnace, radiation heating surface wear of mill, coal tube,

3. Combustion Control
3-1-2 Coal Combustion

Combustion Mechanism of Pulverized Coal

Coal

Volatile CH4, H2, CO

radiation ignition temp.

Char

Low NOx Combustion

1. 2. 3. 4. 5. 6. Reduction of surplus air ratio (high volatile coal; 1.21.25) Lowering combustion air temp. (normally 250350 Two stage combustion (st burner + 2nd burner) Recycling exhaust gas (20~30%) Inner-furnace denitrification 1st Process Low NOx burner furnace HC decomposition O2 existing reductant HC chemical equivalent O2 2nd Process atmosphere temp. reaction temp. of non-burned portion sufficient O2

slow mixture air & fuel promotion of unevenness comb. acceleration of flame heat radiation

3. Combustion Control
3-2-1 Oil Combustion Oil Combustion Mechanism
Flame Combustion Evaporation Comb. + Decomposition Comb. oil air high spraying burner vaporized sub. solids
heat

Comb. reaction oil jet speed combustion speed

Surface Combustion

Effect of Fuel Oil Properties on Exhaust Gas Composition

Subs. Con. wt% Pollutants Damages

N S

0.01~0.6

NOx SO2,SO3SO4 SO Dust

Air pollution Air pollution, corrosion clogging Dust, carbon adhere Scaling, Vanadium attack, corrosion, mechanical wear, etc.
JIS CHeavy Oil

0.2~3.0

Red. C 4.0~11.5 Ash (Na, K, 0.02 V, ----)

Adherents

3. Combustion Control
3-2-2 Oil - NOx Generation NOx Generation and its Control in Oil Combustion

Generation Thermal NOx (N in Air) Flame temp. O2 concentration Retention time Fuel NOx (N in Fuel) O2 concentration Nitrogen in fuel

Control Measures 2-stage combustion Exhaust gas recycling Low NOx burner Furnace size expansion

3. Combustion Control
3-3 Gas Gas Combustion Mechanism
air gas Short flame No-Luminous flame N S0 Impurity 0
e Th rm

NOx
x NO al

no Dust

no SOx

C/H Ratio 7.5 6 3

Heat Radiation Rate large

Heavy crude oil Naphsa Natural gas

small

Control of NOx Generation

Optical information

Oscillating Combustion Preventive Measures

flame

Visual Image Processing

Spectral Analysis

4. Dust Collector
4-1 Type of Dust Collectors
Type Applic. Particle (m) 50 10 3 ~0.1 ~0.1 Operating Cutback Level

d.p.: dew point S: small M: medium L: large

Pressure Drop (mm H2O) 1015 3070 50150 300800 100200 Equipmen t Cost Running Cost

Gravity Inertia Centrifuge Scrubbing Filtration

d.p. 400 d.p. 400 d.p. 400 no-limit no-limit

4060 % 5070 % 10 mgm3 20 mg m3 5 mgm3 or less 5 mgm3 or less

S S M M M

S S M L M

EP

~0.03

d.p. 400

1020

4. Dust Collector
4-2 Gravitational, Inertial & Centrifugal Dust Collector

Stokes Law
m in.

Gravity

section

V=(g/ 18)(1-) D2 (cm/s) V: settling velocity (cm/sec) g: gravitational acceleration (cm/s2) : gas viscosity (kg/ms) 1: particle density (g/cm3) : gas density (g/cm3) D: particle diameter (cm)

cle rti pa

dust

Principle of dust collection ;

Centrifugal force (F) = mv2 /R (N)
m: particle mass (kg) V: particle velocity (m/ s) R: cyclone radius (m) Inertia

Centrifugal

4. Dust Collector
4-3 Scrubbing Dust Collector water drop

Principle of dust collection ;

dust media

water film
demister demister packing water spray disc impact disc

demister

fan runner

Reservoir type

Pressurized Packed bed type water type

Rotary type

4. Dust Collector
4-4 Filter Type Dust Separator Pd P Pi = P + Pth

Typical bag filter unit

clean gas exhaust gas filter bag

twisting aperture 50~10 filter cloth dust layer to thin film dust be shaken off

Type: (1) bag filter (2) cartridge filter Filter cloth: (1) woven fabric (2) nonwoven fabric Dust shake-off: (1) intermittent (2) continuous Apparent filtration rate: 0.3~10cm/s

Filtration Mechanism

4. Dust Collector
4-5-1 Electrostatic Precipitator (EP)

Principle of dust collection

Exhaust gas properties;

inlet soot & dust dust SiO2 C Rate apparent S.G. g/Nm3 m Wt % Wt % cm g/ml Heavy oil Coal 0.05~0.15 10~20 1~3 20~30 15~20 60~75 50~60 0.4~0.8 104~106 1011~1013 0.1~0.2 0.6~0.8

dust collecting electrode

discharge electrode

- - -

- - - -

Influence on dust collection Improving method

NH3 injection SO3 mist temperature water SO3 mist composition of dust

Appropriate

tempering flue gas electric charge control dust removal on (+) electrode selection of gas temp.

4. Dust Collector
versus gas
con duc tion

4-5-2 Factors Working on EP Dust removal versus cm

jumping normal range reverse ionization

1012
cm

vol e um

dust collection rate % , A, V V

tion duc con

sur

fac e

10

H2O SO3

larger

gas temp.

104

cm

1011

Advantages and disadvantages of EP

Advantages large gas volume fine particles of submicron high temperature gas wet type dust collection suitable operation inexpensive maintenance Disadvantages initial cost expensive affection of apparent (- Cm) system size- large high level accuracy in manufacturing

4. Dust Collector 4-6 Ash Treatment

Fly ash ECO Boiler COAL Cinder Clinker
Silo

AH

OIL EP EP ash

Boiler

bottom ash EP little

dehydrator
Fine particle Coarse particle Raw particle

Settling T. Water T.

landfill raw material for cement fishery and agriculture industries others

valuable materials recovery for cement production

5. Flue Gas Desulphurization

5-1 Flue Gas Desulphurization Methods (FGD) Method Absorbent/ Adsorbent NaOH or Na2SO3 solution NH3-water Slaked lime or limestone slurry Mg(OH)2-slurry Basic Al2(SO4)3-solution Dilute-H2SO4 Dry type Activated carbon Byproducts Na2SO3, NaNO3, SO2, gypsum (NH4)2SO4, SO2, gypsum, S gypsum SO2, gypsum (blended with
slaked lime slurry)

Wet type

gypsum gypsum (NH4)2SO4, gypsum, S, H2SO4

limestone cheap initial & operating cost economics system stability & safety gypsum stable sales

most popularly used method in Japan

Lime & Gypsum Method

5. Flue Gas Desulphurization

5-2 Wet Type Lime & Gypsum Method FGD System
limestone slurry Powder 50~60m concentration 10%

Boiler

FGD

EP
GGH

SOx
CaSO3, CaCO3, CaO,CaSO4

air oxidation tank

absorption tower

Reaction Mechanism SO2 + CaO CaSO3 2CaSO3 + O2 2CaSO4 CaCO3 + SO2 CaSO3 + CO2

gypsum crystal dehydrator

5. Flue Gas Desulphurization

5-3 Simplified FGD System Comparison of Simplified FGD with Conventional FGD
Lime & Gypsum Method Alkali Ca CO3 powder SO2 + H2O H2SO4 H2SO3 + 1/2O2 H2SO4 CaCO3 + H2SO4 + H2O Simplified FGD Semi-dry Method Intrafurnace Desulphurization

+ Water Spray Method Reaction

CaCO3 powder CaCO3 CaO + CO2 SO2 + CaO + 1/2O2 CaSO4 SO2 + CaO + 1/2H2O CaSO3 + 1/2H2O no wastewater compact size, less space simple process, excellent in economics slagging inside boiler lower removal lower alkali utilization

useful gypsum Advantages large flue gas high-level removal wastewater treatment Disadvantages anticorrosion material large area high maintenance cost Cost Equipment Operation

CaSO4 + 2H2O + CO2

100 100

20~30 75~80

6. Flue Gas Denitrification

6-1 NOx Abatement Method

Reduction of NOx Generation & Denitrification Methods

Method Applicability Flue gas recirculation T-NOx Low NOx burner F-NOx, T-NOx Staged burners F-NOx, T-NOx SCR F-NOx, T-NOx SNCR F-NOx, T-NOx NOx red. (%) 70~80 10~25 40~70 80~90 60~80

T-NOx: Thermal NOx F-NOx: Fuel NOx

Denitrification Process Process

Dry Process SCR (Selective catalytic reduction) SNCR (Selective non-catalytic reduction) NSCR (Non-selective catalytic reduction) Catalytic cracking Wet Process

Method
NH3, catalyst NH3, Gas temp. 800~ 1,000 catalyst (Pt) + CH4,or CO, or H2 catalyst (Pt,) NOx + SOx removal complicate process wastewater treatment

6. Flue Gas Denitrification

6-2 NH3 Catalytic Reduction Process

NH3 NOx NH3 EC NOx Boiler

SCR Process
Ammonia Catalytic Reduction Process

Catalyst 300~400

N2 H 2O

AH

Catalyst support: ceramic (Ti, Al, ) catalyst: metals shape: granule, grid-form honeycomb, plate control: denirification rate catalyst bed draft loss

Fan

Reaction 4NO +4NH3 + O2 4N2 + 6H2O 2NO2 + 4NH3 + O2 3N2 + 6H2O

to EP

7. Stack
Stack height & Draft force

(a gH0 Peb Vg22g g + h 0

(a gH0: theoretical draft force (kg/m2) a: air specific weight at atmosphere temp. (kg/m3) g: exhaust gas H0: stack height from datum level (m) Peb: effective blower pressure (kg/m2) Vg: exhaust gas outlet velocity (m/s) g: gravitational acceleration (m/s2) h: total pressure loss in exhaust gas route = V22g g (kg/m2) : resistance coefficient V: flue gas velocity in route (m/s) steel stack RC stack

single self support

steel tower support

multi-cylinder

single

concentration

8. Environmental Management System

1. Environmental Management System EMS - Trend of environmental management - Organization for env. management & control - Mission - Pollution control system 2. Cooperation with Local Government - Cooperation in pollution control measures - Handling of complaints - Env. protection agreement 3. Data disclosing 4. Education and Training of Employees 5. Monitoring 6. Greening of Power Station 7. Measures against Accident and Emergency - Accident - Emergency

ISO 14000

9. Energy Saving
1990
42~44%

2000

2010
Efficiency improvement = Energy saving = Pollution decreasing 44~46%
Advanced A- FBC

Steam turbine Fluidized bed combustion Gas turbine Coal gasification Direct power generation

Super C

USC

44~46%
A- FBC P- FBC

44%
LNG 1100 Gas Turbine

47%
LNG 1300 Gas Turbine

50%
LNG 1500 Gas Turbine

44~48% Gasification technology 35~40%

PAFC IGCC 1300

48~50%
IGCC 1500

50%
MCFC

50%
SOFC

50%
IGFC