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Babcock-Hitachi K.K. 1 All Rights Reserved Copyright (C) 2012, Babcock-Hitachi K.K.

Wet Flue Gas Desulphurization SystemWet Flue Gas Desulphurization System

MarchMarch 1122, 2012, 2012

BabcockBabcock--Hitachi K.K.Hitachi K.K.

Promising to contribute to global welfarePromising to contribute to global welfarewith technologies of energy and environment systemswith technologies of energy and environment systems

Introduction of Babcock Introduction of Babcock - - Hitachi K.K.Hitachi K.K.

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1. General Information1. General Information

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Power Systems Company of HITACHI Power Systems Company of HITACHI

Nuclear Power Business Others

Thermal Power Business

Central Contro l Panel

(ABWR, ESBWR)

Preventive Maintenance, Fuel Cycle, etc.

Wind Power Sys. Solar Power Sys.

Hydro Power Sys.

Power Device

PBT Smart Grid,Transmission &DistributionSystemPET Service, etc.

AQCSCoal Fired PP

GTCC, Preventive Maintenance, etc.

Gas TurbineCO2 Capture Solution

Nuclear EquipmentRPV

Major Equipment

20%20%

FY2010

SALES

¥813.2B

60%

Blue : Products of BHK

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Outline of Babcock Outline of Babcock - - Hitachi K.K.Hitachi K.K.

- Established 1953

- Employees 3,200

(Worldwide)

- Head Office Tokyo, Japan

- Works

Kure 1st & 2nd, Noumi, Akitsu

Philippine (BHPI), China (BHDB)

- Laboratories

Kure, Akitsu

- Affiliated CompaniesDomestic : 2 / Overseas :3

- Quality Certificates

ISO 9001, ISO 14001,

ASME S, U and U2

Babcock-Hitachi K.K.

Segment of

Power & Environmental

in Hitachi group

Stock holder: Hitachi Ltd.

(100%)

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Company History Company History

Hitachi, Ltd.Hitachi, Ltd. B&W UKB&W UK

19081908

19271927

1928192819531953

19591959

19611961

19641964

1965196519711971

19751975

19781978

1987198719951995

BabcockBabcock--Hitachi establishedHitachi established

Kure Branch Works became independent from Hitachi WorksKure Branch Works became independent from Hitachi Works

Totally independent from Hitachi Ltd.Totally independent f rom Hitachi Ltd.

Corporate name changed toCorporate name changed to

Toyo Babcock Ltd.Toyo Babcock Ltd.

Hitachi Works Boiler ManufacturingHitachi Works Boiler ManufacturingDepartment establishedDepartment established

Hitachi Works Kure Branch Works establishedHitachi Works Kure Branch Works established

Zenma Works Ltd.Zenma Works Ltd.establishedestablished

[Expansion on Production Locations]

1987 Akitsu Works

1989 Noumi Works

1989 Philippines (BHPI)1996 China (BHDB)

[Expansion on Production Locations]

1987 Akitsu Works

1989 Noumi Works

1989 Phil ippines (BHPI)

1996 China (BHDB)

MergedMerged CapitalCapital…… ¥ ¥1,235million1,235million）

Share Holding Ratio amounted toShare Holding Ratio amounted to

100% of Hitachi, Ltd.100% of Hitachi, Ltd .

(Capital(Capital…… ¥ ¥ 1,852.5 million)1,852.5 mi llion)

(Capital(Capital…… ¥ ¥ 2,637.5 mi llion)2,637.5 mi llion)

(Capital(Capital…… ¥ ¥ 3,000 million)3,000 million)

(Capital(Capital…… ¥ ¥ 5,000 million)5,000 million)

20052005

20062006

Hitachi Power Systems America (HPSA) establishedHitachi Power Systems America (HPSA) established

BabcockBabcock BorsigBorsig Power Systems (BBPS ) acquiredPower Systems (BBPS ) acquired20032003

20112011

Hitachi Power Europe (HPE) establishedHitachi Power Europe (HPE) established

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Main Products Main Products

Integrated &

Dedicated

Product Line-up for

Power and Industrial

Plant

Power Boilers

HRSG

Industrial Boiler FGD SCR Nuclear Power

Industrial Plants

Incinerators

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Hitachi Power Systems America, Ltd.

(HPSA)Basking Ridge, NJ, USA

Engineering, procurement and sales ofboilers and Air Quality Control System

(AQCS)

Hitachi Power Europe GmbH (HPE)Duisburg, Germany

Engineering, procurement, manufacturing and

sales of boilers, AQCS and related equipment.

Works Worldwide Works Worldwide

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FGD retrofitsFGD retrofits – – HITACHI formation HITACHI formation

Local partner

Sub-Contractors

Joint & Several

Consortium

Babcock-Hitachi K.K.Hitachi Power Europe

Customer

EPC contract

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Knauf Gips KG

Sub-Contractors

Babcock Hitachi K.K.

Hitachi Power Europe GmbH

EPCcontractOff-take contract

Cooperation

FGD retrofitsFGD retrofits– – complete solution on cooperation withcomplete solution on cooperation with Knauf Knauf Gips Gips

Customer

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Knauf Reference Example Knauf Reference Example

Gypsum wall board plant near the power station

power

stationFGD Gypsum

store

Gypsum Wall

Board plant

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Japanese regulation of flue gas treatment Japanese regulation of flue gas treatment

Dust：

20mg/m3N D u s t C o n

c .

( m g / N m ³ )

S O 2 C o n c

. ( p p m )

1980 1990 1995 2000 2005 2010

20

40

60

80

100

0

(Year)

10mg/m3N

Dust:5 mg/Nm3

SO2:100ppm (285mg/Nm³)

SO2:25 ppm (71mg/Nm³)

Dust:10mg/Nm3

NOx:35ppm (71mg/Nm³)

SO2：50ppm (142mg/Nm³)

NOx：

50ppm (103mg/Nm³)

Dust:20mg/Nm3

NOx:70ppm (144mg/Nm³)

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Air Quality Control System (AQCS) Air Quality Control System (AQCS)

Boiler DeNOx(SCR) FGD

ESP

FGD : Flue Gas

DesulfurizationBoilers DeNOx(SCR)

ESP

FGD

Stack

Hitachi is one offew AQCS Supplier

for total system

Hitachi is one offew AQCS Supplier

for total system

AQCS Air Quality Control Systems

Stacks

(Layout for 1000MW coal fired plant in Japan)

A/H

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Measures for SO Measures for SO 2 2 Reduction Reduction

Circulating Dry Scrubber (CDS)Limestone Injection into Furnace and Flue

Gas Humidification

Activated coke method

Sea water method

Magnesium Hydroxide -Gypsum methodWet ProcessLimestone-Gypsum method

Spray Dryer Absorber (SDA)

Semi-Dry Process

Fly ash method

Activated carbon method

Dry Process

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Reasons for the wide appl ication 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

FGD Process: FGD Process: Wet Limestone Wet Limestone - - Gypsum Process Gypsum Process

* also quick lime technology available (Walsum Power Plant - Branntkalk)

Technical Response to Emission regulations

Forced oxidation limestone gypsum process as almost standard technology

(after technological and economical comparison)

Performance optimisation and cost reduction results in highly standardised absorber

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2. Babcock-Hitachi’s WFGD Technology

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Development of Hitachi WFGD System Development of Hitachi WFGD System

PERFORATED

TRAY TOWER

SPRAY TOWER

R&D / PILOT

ADVANCED SPRAY TOWER

MATSUURA #1 – 1,000MW TACHIBANAWAN #2 – 1,050MWMATSUSHIMA #2 – 500MW

TRAY TOWER SPRAY TOWER ADVANCED SPRAY TOWER

1962 1970 1975 1995 2000 20051980

PERFORATED TRAY TOWER SPRAY TOWER ADVANCED SPRAY TOWER

Initial StageImprovement of Reliability

Targeting Low Utility and CostReduction of Utility

TAMASHIMA #3 – 500MW

2010

LIMESTONE GYPSUM FGD SYSTEM

2015

Simplification of the System

Meeting Middle Load Ope.

1985 1990

COMMERCIAL PLANT ( Total 15, - COAL 3, OIL 12 )

COMMERCIAL PLANT ( Total 9, - COAL 4, OIL 3, COM 1, PET COKE 1 )

COMMERCIAL PLANT

( Total 52, - COAL 41, Lign ite 3 ORIMULSION 2, OIL 2, PET COKE 2, R.O. 2 )

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BHK FGD can be applied to

any kinds of fuel and

various sulfur containing fuel

・ Applied many kinds of fuel

・Experience of high sulfur fuel

Wide Application of BHK WFGD System Wide Application of BHK WFGD System

OIL

BHK FGD SYSTEM

ORIMULSION P. C.

FUEL

BHK'S EXPERIENCE

1. OIL

2. COAL

3. COM

4. ORIMULSION

5. RESIDUE OIL

6. PET.COKE

1000 2000 500040003000INLET SO2 CONCENTRATION (ppm)

COAL / LIGNITE

RESIDUAL OIL

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Pri Pri nciple and System Flownciple and System Flow of of BHK Wet FGD System BHK Wet FGD System

WASTE

WATER

ABSORBER

AIR

BOILER

ESP

GAS-GAS HEATER

STACK

LIMESTONE

GYPSUM

DEWATERING

GYPSUM

FAN

LIMESTONE MILL

ABSORPTION SYSTEMGYPSUM RECOVERY SYSTEM

LIMESTONE PREPARATION SYSTEM

SO2+2H2O+CaCO3 (LIMESTONE) + 1/2O2 CaSO4•2H2O(GYPSUM)+CO2

CHEMICAL PRINCIPLE: SO2 Absorption and Oxidation

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Absorption system Absorption system



WASTE

WATER

ABSORBER

AIR

BOILER

ESP

GAS-GAS HEATER

STACK

LIMESTONE

GYPSUM

DEWATERING

GYPSUM

FAN

LIMESTONE MILL



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ABSORPTION

AREA

GAS

CLEAN GAS

FLUE GAS

AIRTANK AREA

TANK AREA

AIR ;

(GYPSUM)

(LIMESTONE)

･

FLUE GAS

SO2

SO2+2H2O+CaCO3+1/2O2 CaSO4･2H2O+CO2

Pso2

Xso2

SPRAY

NOZZLESLURRY GAS FILM

LIQUID

FILMDROPLET DROPLET

Principle of BHK Advanced WFGD System Principle of BHK Advanced WFGD System

CHEMICAL

REACTION

SO2 Absorpt ion

and OxidationSO2+2H2O+CaCO3 (LIMESTONE) + 1/2O2 CaSO4•2H2O(GYPSUM)+CO2

ABSORPTION

AREA

(Chemical Reaction in Absorber) (Chemical Reaction in Absorber)

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Outline of Babcock Hitachi Outline of Babcock Hitachi ’ ’ s Absorber s Absorber

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Absorber Design Absorber Design

Absorber Outlet

(horizontal or vertical)

Absorber

Inlet

Mist Eliminator

(2 – 3 stages, dependingfrom allowable drop content)

Spray Levels(number of levels depending on sulphur in fuel,

if desired with space for retrofit of spare level)

Absorber sump(with agitator for mixing

and oxidation air injection)

Spray Nozzles(up and/or down spray nozzles)

Absorption Area

SO2 & Dust Removal

Absorber Sump

Oxidation

Dissolution of

Limestone

Crystal growth

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Spec. A Rubber lined 2 x 6 mm

Spec. B Rubber lined 1 x 6 mm

Spec. C Alloy plated

European Solution: Rubber Lined Absorber

Lifetime of more than 50.000 hours,

Maintenance and repair of coating by rubber lining specialist company only !

Absorber MaterialAbsorber Material – – Rubber Lining Application Rubber Lining Application

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Absorber MaterialAbsorber Material – – Flake Lining Application Flake Lining Application

Acid Resistant FRLHeat Resistant FRL

Heat Resistant FRL

or Metal lined

Wear Resistant FRL

or Metal lined

Spark test:Inspection of lining

Primer

1 st layer 2 nd layer

Top coat

Inspection After3 Years Operation

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Limestone Slurry preparation system Limestone Slurry preparation system



WASTE

WATER

ABSORBER

AIR

BOILER

ESP

GAS-GAS HEATER

STACK

LIMESTONE

GYPSUM

DEWATERING

GYPSUM

FAN

LIMESTONE MILL


LIMESTONE SLURRY

PREPARATION SYSTEM

Fl Di fFlow Diagram of

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Flow Diagram ofFlow Diagram ofLimestone Slurry Preparation System Limestone Slurry Preparation System

LimestoneFeeder

H/C

Classifier

Mill Tank

Slurry Pump

Limestone

Limestone

Slurry Tank

Silo

Grinding/ Dilution

Water Supply

DistributionSystem

M

M

M

M

High

Low

WW

W

W

WWater

Main Process

W

W

Ball

Mill

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Limestone PreparationLimestone Preparation - - Wet Ball Mill Wet Ball Mill

- Quarry Ground Limestone or On-Site Mill

- Horizontal Ball Mill or Tower Mill

- 95% - 325 Mesh (44 µm)

- 30% Solids

H 2 S O 4 c o n s u m p t i o n

( = L i m e s t o n e R e a c t i v i t y )

Time

Standard

HorizontalBall Mill

Photo Horizontal Ball Mill

Evaluation of Limestone activity ReliableDesign

･

Limestone Activity Test

G R S tG R S t

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Gypsum Recovery System Gypsum Recovery System



WASTE

WATER

ABSORBER

AIR

BOILER

ESP

GAS-GAS HEATER

STACK

LIMESTONE

GYPSUM

DEWATERING

GYPSUM

FAN

LIMESTONE MILL



Gypsum Recovery SystemGypsum Recovery System

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Hydro-Cyclone

Overflow

Absorber Slurry

Filtrate Receiver Vacuum PumpTo Absorber

Horizontal Belt Filter

Gypsum Recovery System Gypsum Recovery System - - Belt Filter Application Belt Filter Application

Water for

recycling

By product

Gypsum

Gypsum Recovery SystemGypsum Recovery System

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Hydrocyclone

Vacuum Belt Filter

Byproduct Gypsum

Slurry feed

D i rec t i o n

Vacuum

Gypsum Recovery System Gypsum Recovery System - - Belt Filter Application Belt Filter Application

T i l R i t f G UT i l R i t f G U

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BY-PRODUCT GYPSUM QUALITY

PHOTO OF BYPRODUCT GYPSUM CRYSTAL

——0.32 %Ca O3

5~8—6.8pH

0. 03 %—0.001 %Na+

< 0. 25 %—< 0.05 %CaSO3 • 1/2H2O

> 95 %> 90 %98.8 %CaSO4 •2H2O

FOR WALL

BOARD

FOR

CEMENT

ACTUAL

VALUEITEM

GENERAL REQUIREMENTIN JAPAN

Typical Requirement of Gypsum Usage Typical Requirement of Gypsum Usage

R i t f G Q lit i ERequirement of Gypsum Quality in Europe

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NeutralOdour

Non-toxicToxicity

5-9pH

< 0.01Cl

< 0.06Na2O

< 0.10MgO

> 95%CaSO4 •2H2O

WhiteColor

< 0.50 %CaSO3 • 1/2H2O

< 10%H2O

EURO GYPSUM

CriteriaITEM

VGB-M 701e:

EURO GYPSUM: Quality Criteria and analysis methods

Requirement of Gypsum Quality in Europe Requirement of Gypsum Quality in Europe

BY-PRODUCT GYPSUM QUALITY

FGDDesign Consideration for Lignite CoalFGDDesign Consideration for Lignite Coal

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Large Flue Gas Volume

High SO2 Content

High Fly Ash Loading

High Inlet Gas Temperature

High Inlet Moisture

FGD Design Consideration for Lignite Coal FGD Design Consideration for Lignite Coal

*1 Gas Flow Rate shall be confirmed.

High Removal Efficiency

High Absorber Slurry

Temperature

BHK Unique FGDTechnology:BHK Unique FGDTechnology:

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BHK Unique FGD Technology:BHK Unique FGD Technology:Wet Stack Solution Wet Stack Solution

Wet stack on top of Absorber Wet stack on top of Absorber Stand alone Wet stackStand alone Wet stack

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

Absorber

Wet Stack

Absorber

FRPWet Stack

FGDWasteWater Treatment FlowchartFGD Waste Water Treatment Flowchart

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FGD Waste Water Treatment Flowchart (Example in Europe) (Example in Europe)

COAGULANT

Sludge Storage

TankFilter Press

Discharge

to River

Ca(OH)2 Polymer HCl

Raw

FGD

Waste

Water

TMT-15FeCl3

Lamella

Clarifier

Waste Product

SS, Heavy Metals Removal

Neutralization

Tank 1Neutralization

Tank 2

Flocculation

Tank

Treated WasteWater Tank

Coolingwater

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3. Experiences

HITACHIHITACHI’’ss FGDExperiences in EuropeFGDExperiences in Europe

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HITACHI HITACHI s s FGD Experiences in EuropeFGD Experiences in Europe

(800MW x 4)(750MW x 1)(800MW x 2)

(800MW x 1)

(220MW x 1)

(556MW x 1)

Reference Plant Industry RecognitionReference Plant Industry Recognition

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POWER’s 2011 Plant of the Year

- Power Magazine (Oct 2011)

Project of the Year Award

- Power Gen International 2011 in Las Vegas, USA

Reference Plant Industry Recognition Reference Plant Industry Recognition

Ameren Services (USA) / Coffeen Power Plant / No. 1, 2 Ameren Services (USA) / Coffeen Power Plant / No. 1, 2

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4. Research & Development4. Research & Development

R&DFacilitiesR&D Facilities

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R&D Facilities R&D Facilities

Desulfurization Test Facili tyDesulfurization Test Facili ty Boiler-AQCS Pilot Test FacilityBoiler-AQCS Pilot Test Facility

Flue gas

treatment facility

DESP

Combustion

facility

Coal Feed Rate 100~150 kg/h

Gas Flow Rate 1,000~1500 m3N/h

Abs. dia: 480 mm

WFGD SCR

FF WESP

Burner

SCR

GGH

DESP

PumpWFGD

Coal

BUFIDF

WESP

G/C

GGH

FF

CEM

4 Absorbers and 1 Reaction Tank Test Facili ties

e.g.

Absorber A Absorber B-Gas flow: 22,000m3N/h -Gas flow: 250m3N/h

-SO2 conc.: 500 ppm -SO2 conc.: 20,000ppm

-Abs. dia.: 680mm -Abs. dia.: 160mm

Absorber A Absorber B

Computational Flow ModelComputational Flow Model

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< Model Consideration >

- Spray Droplets

- Kinetic Momentum (Droplet/Gas)

Gas Distribution

Confirmation of Optimized Absorber

internal arrangements by Flow Model to

prevent the gas short-pass.Flow Model Results

Track of Spray Droplet

Computational Flow Model Computational Flow Model

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Special Features of BHK FGDSystemSpecial Features of BHK FGD System

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Total Engineering Capabili ty 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 Facil ity

Proven FGD Technology and High Reliability

Special Features of BHK FGD System Spec a ea u es o G Sys e

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SCR Process SCR Process

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4NO + 4NH3 + O2

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

6NO2 + 8NH3 7N2 + 12H2O

REACTION FORMULA

SCR ; SELECTIVE C ATALYTIC REDUCTION

NOx

NOx

NOx

NH3

NH3

NH3

NOx

NOx

N2

N2

H2O

H2O

H2O

CATALYST

CLEAN

GAS

NH3

Scheme of SCR System Scheme of SCR System

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

yy

BOILER

ECO

EP DeSOx

FDF

STACK

NOx ANALYZER

BOILER

LOAD

SIGNAL

NH3 STORAGE TANK

EVAPORATOR

ACCUMULATOR

FICMIXER

SCR Reactor NH3 injection

Catalyst

NH3 Storage & Supply

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Reactor Design

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SCR ReactorSCR Reactor

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SUPPORTING

STRUCTURE

CASING

NH3 INJECTION GRID

INLET DUCT

MAIN MONORAIL

HOIST

OUTLET DUCT

CATALYST BLOCK

Plate Type Catalyst Plate Type Catalyst

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CATALYST BLOCKCATALYST UNIT

CATALYST ELEMENT

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