bhel experience for emission norms below 30...
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Welcome delegates
ROUNDTABLE ON POLLUTION
CONTROL TECHNOLOGY OPTIONS:
COAL POWER STATIONS
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ESP Profile - BHEL Experience…
Application:
Utilities up to 800 MW
Cement, Steel & Fertilizer industries
Chemical Recovery boilers
Bio Mass Application
Glass industries
Fuel Range:
Indigenous / Imported coal
Lignite
Pith
Bagasse
Rice husk / Rice Straw
Bark & All low grade fuels
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Capability:
Gas Flow up to 5.27 million
m3/hr (1465 cu.m/sec)
Emission level as low as
~17 mg/Nm 3
Collection Efficiency as high
as 99.97% and above
Complete Turnkey Systems:
Duct work & Dampers
Support steel structures
Thermal insulation
Integrated Control Systems
BHEL’s ESP Reference List
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APPLICATION NO. OF
PROJECTS
NO. OF ESPs
UTILITY BOILERS - PF Fired - 15 to 660
MW
447 1134
INDUSTRIAL BOILERS – CPP, VU40,
Stoker, etc
104 134
AFBC BOILERS – 25 to 165 TPH 57 57
CFBC BOILERS – 30 to 250 MW 18 33
CHEMICAL RECOVERY BOILERS – 75 to
900 TPD
46 70
OIL FIRED BOILERS -125 MW 3 3
BIOMASS – Upto 20 MW 50 50
CEMENT 16 16
STEEL 11 13
GLASS FURNACE 2 2
LIME KILN – 170 TPD - Paper plant 1 1
REFRACTORY - Magnesite 1 1
TOTAL 746 1514
FACTORS AFFECTING ESP PERFORMANCE
Indian ESP performance Vs Design
Parameters Variation Performance
Gas flow Increases Decreases
Gas temperature Increases Decreases
Inlet dust conc. Increases Decreases
Moisture in gas Increases Increases
Sulphur in coal Increases Increases
Ash Resistivity Increases Decreases
Un-burnt in ash Increases Increases
Particle size Increases Increases
BHEL supplied Electrostatic precipitators are
meeting the required performance levels as per design.
Operating parameters at ESP inlet like
Gas volume,
Gas temperature,
Inlet dust burden,
Coal quality,
Ambient conditions .
not vary much and to be maintained nearer to the design values
otherwise it will affect performance ie, emission will increase.
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Indian ESP performance Vs Design
ESP Upgradation Options –Merits and demerits
EMISSION WILL BE REDUCED BY
AUGMENTATION OF ESP COLLECTING AREA IN FOLLOWING WAYS: INSTALLING ADDITIONAL ESP PASSES IN PARALLEL
INSTALLING ADDITIONAL ESP IN SERIES.
REBUILDING THE EXISTING ESP BY INCREASING CASING HEIGHT
REBUILDING THE EXISTING ESP BY EXTENDING CASING LENGTH AT INLET
/OUTLET SIDE.
TOTAL REPLACEMENT OF EXISTING ESP WITH BIGGER NEW ESP.
RETAINING EXISTING ESP AND ADDING FIELDS IN SERIES AT INLET /OUTLET
SIDE
ENERGISATION WITH MICRO-PROCESSOR BASED
CONTROLLERS:
• INTRODUCTION OF INTERMITTENT CHARGING ESP MICRO
CONTROLLERS –Areca-ii
Providing solutions for a better tomorrow
MERITS AND DEMERITS OF ESP
UPGRADATION
REBUILDING THE EXISTING ESP
KEEPING THE LENGTH AND WIDTH OF THE EXISTING ESP, THE
MORE COLLECTING AREA CAN BE ACCOMMODATED BY
INCREASING THE CASING HEIGHT.
NO ADDITIONAL DUCT WORK AND HENCE NO ADDITIONAL
PRESSURE DROP
LONGER SHUT DOWN OF THE PLANT RESULTS MAJOR
REVENUE LOSS – A MAJOR CONSTRAINT.
ADDITIONAL CARE TO BE TAKEN TO CHECK THE EXISTING
FOUNDATION SHALL WITHSTAND ADDITIONAL LOAD
MERITS AND DEMERITS OF ESP
UPGRADATION
INSTALLATION OF ADDITIONAL ESP IN SERIES OR PARALLEL
NEEDS LESS DOWN TIME OF THE PLANT AS THE INSTALLATION
OF THE ADDITIONAL ESP IS A PARALLEL ACTIVITY
SHUT DOWN IS REQUIRED ONLY FOR HOOKING UP ACTIVITY
ADDITIONAL DUCT WORK AND HENCE THE ID FAN CAPACITY
TO BE CHECKED FOR HANDLING ADDITIONAL PRESSURE DROP
DUE TO ADDITIONAL DUCTING AND ESP CARE SHOULD BE
TAKEN TO ENSURE UNIFORM GAS DISTRIBUTION
Revised MOEF Notification dt 7th December 2015 Pollutants TPPs ( units) installed
before 31st December, 2003*
TPPs ( units) installed
after 1st January,2003,
upto 31st Dec , 2016*
TPPs ( units) to be installed
from 1st Jan, 2017**
Norms till 7th December 2015
Particulate Matter (PM)
100 mg/Nm3 50 mg/Nm3 30 mg/Nm3 100 mg/Nm3
Sulphur Dioxide (SO2)
600 mg/Nm3 (Units Smaller than 500MW
capacity units) 200 mg/Nm3 (for units
having capacity of 500MW and above)
600 mg/Nm3 (Units Smaller than 500MW
capacity units) 200 mg/Nm3 (for units
having capacity of 500MW and above)
100 mg/Nm3 Not Specified
Oxides of Nitrogen NOx)
600 mg/Nm3 300 mg/Nm3 100 mg/Nm3 Not Specified
Mercury ( Hg) 0.03 mg/Nm3(for units having capacity of 500MW and above)
0.03 mg/Nm3 0.03 mg/Nm3 Not Specified
*TPPs (units) shall meet the limits within two years from date of publication of this notification. **Includes all the TPPs (units) which have been accorded environmental clearance and are under construction”.
TYPICAL 210 MW- REBUILDING ESP AND ADDING NEW ESP IN PARALLEL
New taller parallel ESP
Providing solutions for a better tomorrow
UPGRADATION OF ESP – BY EXTENDING CASING LENGTH &
CASING HEIGHT
CASING LENGTH EXTENSION
CASING HEIGHT INCREASE
Providing solutions for a better tomorrow
REFERENCE LIST OF RETROFIT ESPs SUPPLIED BY BHEL
Sl. No. UNIT RATING No. OF UNITS
1. 200 MW & ABOVE 8
2. 100 MW to 120 MW 45
3. LESS THAN 100 MW 48
4. INDUSTRIAL BOILERS 31
5. CEMENT & MAGNESITE 14
6. IRON & STEEL 3
7. CHEMICAL RECOVERY 3
TOTAL 152
ARECA ii Latest BHEL’s micro controller for ESP
Features Integrated controller with rapping control
Faster optimisation
Wireless Communication for IOS
Motor on & off command from the Areca ii controller.
Only two wire communication to link the controllers with the
IntelliRelay and IntelliBuffer cards
On any field failure, rapping operation will be continued with the
respective Program Set number
Redundancy can be provided for IntelliRelay card
Remote monitoring and control is provided in IOS PC using
wireless / serial communication
Areca-ii BHEL’s micro controller for ESP
It improves ESP performance by:
Increased agglomeration of
finer fly ash particles
Increase moisture absorption on
the dust particle, particle
cohesion and there by reduces
electrical resistivity of fly ash
Improved electrical operating
properties of ESP fields.
Ammonia Flue gas conditioning system
Providing solutions for a better tomorrow
Bag filter designed and supplied by BHEL
Sl. No. PROJECTS APPLICATION
1. BHEL, HARDWAR FUME EXTRACTION SYSTEM
FOR STEEL FURNACES
2. KORADI, UNIT -5 210 MW- THERMAL POWER
PLANT
3. ISPAT SIDEX, ROMANIA STEEL PLANT
4.
KONIAMBO NICKEL,
NEW CALIDONIA
3X135MW CFBC BOILER
Technical and economic challenges:
Technical challenges:
Space constraints. It involves dismantling & relocating / rerouting existing facilities like pipe & cable racks, steam piping.
Dismantling of duct support columns and providing temporary supports
Strengthening of supporting structures to take care of wind loads seismic loads
Foundation design taking care of specific site constraints like nearest foundation, ash slurry trenches
Erection of ESP in limited space available by employing tower type cranes.
Flow distribution among existing ESP and new ESP pass installed in parallel
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Technical and economic challenges:
Economic challenges:
Unit generation loss when ESP pass is isolated for
up gradation due to Unit running at partial load .
It involves dismantling & relocating / rerouting
existing facilities like pipe & cable racks, steam
piping.
Dismantling & construction of ESP control room in
new location to provide space for Additional ESP
Upgradation of ID fan in case of ESP addition in
series
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ESP – Flow Model Study
Flow distribution ensures by conducting
physical flow model study
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ESP– CFD Model Study
Flow distribution ensures by conducting CFD model
study
BHEL is capable of meeting the new MOEF norms of particulate
emission level below 30mg/Nm3
Conclusion
Thank
You
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