fecto cfpp presentation updated 13-3-15
TRANSCRIPT
FECTO Cement LimitedA N a m e o f F a i t h
FECTO Cement Limited
PRESENTATION ON
15MW COAL FIRED POWER PLANT
FOR
FECTO CEMENT LIMITED
PRESENTATION BY
MR. NAVEED SABIRASSISTED BY
KASHIF MAHMOOD
FECTO Cement LimitedIntroduction
Fecto Cement Limited (FCL) was incorporated back in 1981 as a public limited
company and is the flagship company of the FECTO Group. The FECTO Group has
diversified business interests spanning across various sectors including cement,
paper products and exploration technology businesses.
FCL is currently involved in the production and marketing of Clinker and Cement with
an existing production capacity of 819,000 tonnes per annum and achieved almost
97% capacity utilization in 2013. FCL enjoys a good market standing with sales both
to local and export markets (India & Afghanistan). In FY 2013, FCL posted net sales
of PKR 4.3 billion.
FECTO Cement LimitedCement Plant Location and Layout
FECTO Cement is rated as the premium brand in the market as per customer’s
choice. Location of the Plant is an added advantage for FECTO Cement being very
close to continuously developing Rawalpindi / Islamabad.
Fecto Cement Plant consists of following sections
Raw Material Crushing and Stacking.
Raw Material Grinding and Storage.
Fuel Grinding and Storage.
Raw Material Calcination and Clinker Storage.
6MW Waste Heat Recovery Power Plant.
Clinker Grinding and Cement Storage.
Cement Packing.
Plant Layout
FECTO Cement LimitedCoal Reserves in Pakistan
God has blessed Pakistan with immense coal resources of more than 185.5 billion
tons and if half of these resources are exploited properly it would be sufficient for
generating 100,000MW of electricity for thirty years. It is unfortunate that so far only
150 to 200MW Power Plants based on indigenous coal has been set up and that is
too in the public sector.
Coal is Pakistan’s domestic resource and we are among the first few having huge
coal resources. In Pakistan we are trying to meet our Power requirement from most
scarce and expensive resources Oil and Gas (opposite to worldwide pattern). Coal
which contributes Worldwide 39% to meet Power requirement, contributes almost NIL
for Pakistan.
Present Power Source
Pakistan Worldwide
FECTO Cement LimitedElectricity Requirement in Pakistan
For the last ten years the economy of Pakistan has grown at an average rate of about
6% per year. This growth has been fueled by large increases in power generation,
distribution and consumption. Load shedding has become a necessity due to
deterioration in the quality of electric service measured both in frequency and
duration of outages and in voltage instability. The National electric generation
capacity has become inadequate and the electric power capacity deficit would
become major setback by the year 2020.
Current Power Production 14,000MW
Current Power Need 18,500 MW
Year 2020 Power Need 26,000 MW
The short fall of electricity has damaged the entire socio-economical outlook of the
country. Energy demand in Pakistan is increasing day by day at a rate of 8 to 10%
per annum. And the gap between demand and supply has always been increasing in
last decade. The answer to this problem lies in exploitation of most indigenous
resources of the country i.e. Coal.
FECTO Cement LimitedIntroduction of Coal Fired Power Plant (CFPP)
Fecto Cement Limited is continuously doing their utmost efforts to participate in
reducing the electric power deficit in Pakistan as well as in creating a clean
environment in the vicinity of Islamabad.
In 2009~2010 Fecto Cement Limited has successfully installed and commissioned a
6MW Waste Heat Recovery Power Plant, based on the technology of utilizing the hot
air of the pyro-process. During cement manufacturing high temperature gasses of the
kiln process which previously were being wasted to the atmosphere has been
captured to generate steam for power generation ultimately making Fecto Cement
Limited an environment friendly plant.
As the private sector can play a vital role in reducing the electric power capacity
deficit in Pakistan. In order to protect their industry from load shedding and
unforeseen grid problems the private industries are importing and installing on site
small scale coal fired captive power plants as per current Government policy.
Fecto Cement Limited is planning to install a 15MW Coal Fired Captive Power Plant
to meet the electricity requirement of Cement Plant, which is designed on the latest
technology of Coal Fired Power generation and is environment friendly.
Video
FECTO Cement Limited15MW Coal Fired Power Plant Configuration
The sanctioned electrical load from WAPDA for Fecto Cement Limited grid is 19MW .
The electricity requirement for the operation of Fecto cement plant is about 17MW.
The Coal Fired Power Plant will be installed in synchronization mode with Fecto grid
as well as 6MW Waste Heat Recovery Power Plant. Total Electricity generation from
15MW Coal Fired Power Plant and already in operation 6MW Waste Heat Recovery
Power Plant(after the self power consumption) would easily meet the power
requirement of Cement Plant.
According to the power supply requirement and main construction conditions of
cement plant, the Power Plant configuration shall be one set of 75 ton per hour
circulation fluidized bed boiler and one set of 15MW condensing steam turbine and
generator. As the Coal Fired Power Plant is a pure thermal power plant considering
operation efficiency, safety, stability and environment conditions the project is
selected having sub-high pressure steam parameters.
FECTO Cement LimitedMain Technical Indexes of Coal Fired Power Plant
Rated Installed Capacity 15 MW
Net Power Supply(after self consumption) 12.6 MW
Annual Designed Operation Time 300 days
Power Plant overall thermal efficiency 33 ~ 35 %
Average Self Power Consumption Rate 12 ~ 16 %
Coal consumption for Power Generation 0.494 kg/Kwh
if the coal heat value is 6,000 ~ 6500 Kcal/Kg (7.41 Tons/hr)
Coal consumption for Power Generation 0.539 kg/Kwh
if the coal heat value is 5500 ~ 6000 Kcal/Kg (8.09 Tons/hr)
Coal consumption for Power Generation 0.593 kg/Kwh
if the coal heat value is 5000 ~ 5500 Kcal/Kg (8.90 Tons/hr)
Coal consumption for Power Generation 0.659 kg/Kwh
if the coal heat value is 4000 ~ 5000 Kcal/Kg (9.89 Tons/hr)
Steam consumption rate 4.1 kg/Kwh
Size of coal to be fed to boiler 0-10 mm
limestone consumption ~1.2 Ton
Size of limestone powder 0~2 mm
FECTO Cement Limited Flyash content ~2.81 Ton
Bottom ash content ~1.204 Ton
Annual power generation 108000 MWh
(Based on annual running 7,200h of cement line)
Annual power supply 90720 MWh
(Self-use power consumption rate of max 16%)
Annual Flyash production 31,920 Ton
Annual boiler bottom ash production 17,480 Ton
Annual coal consumption (Heating value of 4,000kcal/kg) 95,760 Ton
Annual limestone consumption 27,360 Ton
Annual water consumption @ 100.55 T/H 723,976 Ton
Annual 40%NaOH consumption 58 Ton
Annual 36%HCl consumption 79 Ton
Annual 98%Na3PO4 consumption 20 Ton
Annual ammonia water consumption 18 Ton
Annual steam turbine oil consumption 20 Ton
Annual chemicals consumption for circulating water 13 Ton
Annual diesel consumption 150 Ton
Total Land Occupation 15600 sq. meter
Project Completion Schedule 18 months after L/C
Posts and Staff 80
FECTO Cement LimitedCFPP Layout and Equipment Detail
General layout of power plant CFPP Layout
1x75 T/h subordinate high-pressure CFB boiler and auxiliary system
1x15 MW condensing steam turbine(reaction type) generator unit and aux. system.
Coal Storage and handling system
Limestone storage and handling system
CFB Boiler and combustion system
Boiler feed water DM/RO system
Circulation Water cooling system
Fly ash handling system
Bottom ash / slag handling system
Flue gas treatment system
Electrical and power distribution system
Automation Control system
Outdoor steam and water system with heat insulation.
Water supply and drainage system
Heating ,Ventilation and Fire Fighting system
Compressed air system
FECTO Cement LimitedOperation Systems of 15MW Coal Fired Power Plant
1. Thermodynamic System
2. Combustion System
3. Boiler Steam and Water System
4. Boiler Gas and Air Flow System
5. Boiler Ignition and Natural Gas System
6. Boiler Fuel Feeding System
7. Boiler Auxiliary System
8. Steam Turbine and Generator System
9. Coal Handling System
10. Flyash and Bottomash Handling System
11. Plant Circulation Water System
12. Demineralization, RO System and Laboratory and Testing System
13. Electrical, Instrumentation and Automation System
14. Emissions/Flue Gas Analysis System
15. Flue Gas Desulphurization System
FECTO Cement LimitedCirculation Fluidized Bed Boiler
Fluidized bed combustion has emerged as a viable alternative and has significant
advantages over the conventional firing system and offers multiple benefits. Some of the
benefits are compact boiler design, fuel flexibility, higher combustion efficiency and
reduced emission of noxious pollutants such as SOx and NOx. The fuels burnt in these
boilers include coal, washery rejects, rice husk, bagasse and other agricultural waste.
Fluidized bed boilers have a wide capacity range – from 0.5 T per hour to over 100 T per
hour.
FECTO Cement LimitedCFB technology utilizes the fluidized bed principle in which crushed (6-10 mm size)
fuel and limestone are injected into the combustor. The particles are suspended in a
stream of upwardly flowing air (60-70 per cent of the total air), which enters the
bottom of the furnace through air distribution nozzles. The fluidizing velocity in
circulating beds ranges from 3.7 to 9 m/s. The balance of the combustion air is
admitted above the bottom of the furnace as secondary air. The combustion takes
place at 840-900 oC, and the fine particles (<450 microns) are elutriated out of the
furnace with flue gas velocity of 4 m/s. The particles are then collected by the solid
separators and circulated back into the furnace. Solid recycle is about 50 to 100 g per
kg of fuel burnt. The circulating bed is designed to move a lot more solids out of the
furnace area and to achieve most of the heat transfer outside the combustion zone –
convection section, water walls, and at the exit of the riser.
The particle circulation provides efficient heat transfer to the furnace walls and longer
residence time for carbon and limestone utilization. Similar to pulverized coal (PC)
firing, the controlling parameters in the CFB process are temperature, residence time
and turbulence.
FECTO Cement LimitedFor efficient large units, the taller furnace characteristics of CFB boilers offer better
space sorbent residence time for combustion and SOx capture, and easier
application of staged combustion techniques for NOx control. CFB boilers are said
to achieve better calcium to sulphur utilization. CFB boilers are generally claimed to
be more economical than other boilers for industrial applications. CFB requires
huge mechanical cyclones to capture and recycle the large amount of bed material.
At right fluidizing gas velocities, a fast recycling bed of fine material is
superimposed on a bubbling bed of larger particles. The combustion temperature is
controlled by the rate of recycling of fine material. Hot fine material is separated
from the flue gas by a cyclone and is partially cooled in a separate low velocity
fluidized bed heat exchanger, where the heat is given up to the steam. The cooler
fine material is then recycled to the dense bed.
A CFB boiler could be a good choice if the following conditions are met:
• Capacity of boiler is large to medium,
• Sulphur emission and NOx control is important,
• The boiler is required to fire low-grade fuel or fuel with highly fluctuating fuel
quality.
FECTO Cement LimitedCombustion System
When cold start, the inert material shall be in size of 0-4mm, average in 1-2mm. Gas
would go to furnace through air distributor and startup inert material When the bed
temperature rise to about 320oC, coal is fed by feeding devices.
Combustion air would be sent into furnace. Primary air blow into combustion chamber
together with fluidized fuel. Secondary air blow into furnace to regulate combustion.
The classified air distribution would build up a revivification environment to restrain
generation of oxidation process of nitrogen and would finally lower NOx generation.
Under bed temperature, air, fuel, and limestone mixed completely. Fuel burning
would release heat energy, limestone calcinate into CO2 and CaO. Gas, together with
un-burned fuel, limestone and sand would go into Separator to separate. After
separation, gas containing some fly ash would go through cylinder into back path to
heat high temperature super heater, low temperature super heater, economizer and
air preheater, the final emission gas temperature will drop to 145oC. Ash separated
by Separator would go back into furnace to burn again. The furnace material
concentration could be regulated through controlling on slag discharge. The whole
gas and air system adopt balanced ventilation and the balanced pressure point is
near outlet of furnace. The bottom ash as it comes out of the combustor is normally at
the high temperature of the bed. A cooling arrangement is integrated with the
combustor to lower the ash temperature to a value acceptable to the bottom ash
conveying system.
.
FECTO Cement LimitedSteam and Water Circuit
FECTO Cement LimitedTurbine Generator Unit
The steam turbine selected is reaction turbine which will be a standard multistage,
single-cylinder, non-reheat, condensing unit, with two uncontrolled extractions for
regenerative feed heating. In this type, steam entering at high / medium pressure is
extracted at an intermediate pressure in the turbine for process use while the remaining
steam continues to expand and condenses in a surface condenser and work is done till
it reaches the condensing pressure (vacuum). In extraction-cum-condensing steam
turbine as shown in figure below, high pressure steam enters the turbine and passes
out from the turbine chamber in stages. In the process of two stage extraction cum
condensing turbine MP steam and LP steam pass out to meet the process needs.
Balance quantity condenses in the surface condenser. The energy difference is used
for generating power. This configuration meets the heat-power requirement of the
process.
FECTO Cement LimitedMain Steam Turbine Technical Parameters
Type: NK40/56 Reaction Condensing Steam Turbine
Rated rotation speed: 7000 rpm
Rated power: 15 MW
Main stream inlet pressure: 6.1 MPa
Main stream inlet temperature: 470°C
Rated inlet steam flow: 62 t/h
Stage I extraction flow: 4.7 t/h
Stage II extraction flow: 6.8 t/h
Exhaustion flow: 50.5 t/h
Exhaustion pressure: 10 Kpa (0.1ata)
Stage of heaters: one LP, one Deaerator
Feed water temperature: 150°C
Steam rate: 4.10 kg/kWh
The turbine will be connected to generator through gear box operating at 7000/3000 rpm
electrical Power is generated at 6.6KV, 3 phases, 50 Hz. This will minimize the overall
cost of the project. A static excitation system will be used.
FECTO Cement LimitedAuxiliary Equipments of Coal Fired Power Plant
Coal and Lime Stone Storage Yard
The type of coal to be used for 75 t/h Steam Plant is bituminous coal with heating
value around 4000 – 5000 KCal/kg local coal and 5800/6700 Kcal/Kg imported coal.
Hourly consumption is 12t//h.
The coal will be delivered via truck transportation to the coal yard. The coal yard is
designed for storage coal volume for 21 days operation with closed shed and total
storage volume of app. 6800 ton. The coal yard is equipped with water sprinkling
system (pipes with nozzles) to suppress the dust during loading and unloading.
Limestone Storage yard is of the capacity 1600 tons.
Coal Bin
One set of coal bin with 240 m3 will be equipped for boiler. They can meet 12 hours
coal consumption (design coal).
Limestone Bin
One set of Limestone bin with 20m3 will be equipped for boiler. They can meet 12
hours limestone consumption.
Coal Feeder
Two sets of coal feeder will be located for boiler, capacity: 0-10t/h for each. In normal
condition these two coal feeders will be in operation. The coal feeder is fulfilling with
metering automatically.
FECTO Cement LimitedBag Filter
A bag filter will be used as dedusting device. The inlet flue gas temperature is 145 ℃，flow volume is about 160000-180000m3/h. For the design coal, the bag filter efficiency
shall be not less than 99%.
Stack
A single structure 100 m height, with one line made from concrete will be constructed
for the 75 t/h boiler. The stack will be provided with access ladder, obstruction light
(aircraft warning light), port or test hole for online monitoring equipment for flue gas
emissions.
Fly Ash System Fly ash quantity: 2.8 t/h
Fly ash that accumulates in the bag filter and the economizer hoppers will be conveyed
to the ash disposal area via ash handling system, A fly ash silo with capacity of 1000
tons will be equipped with bag vent filter, fluidizing air admission port, ultra sonic level
monitor etc. Additional dust suppression equipment will be employed as necessary to
further control fugitive dust.
Bottom Slag System Bottom slag quantity: 1.2 t/h.
The slag from the boiler will be transported by slag conveyor with water-cooling at the
bottom of the boiler and it will be transferred into slag bin with capacity of 200 ton by
bucket elevator..
Both fly and bottom ash will be used as raw material in the cement plant.
FECTO Cement LimitedAsh, Slag and Desulfurization System
FECTO Cement LimitedCondensing Equipment
The two-pass, surface condenser will be capable of maintaining the design vacuum of
10Kpa (0.1ata) with a maximum water temperature of 32°C, while condensing steam
at the guaranteed rating of the turbine. The condenser will be mounted directly below
the turbine.
Two main condensate pumps (one operating pump and one stand-by) are provided
which extract the condensate from the condenser hot well and pump it through the
gland steam condenser and LP heaters into the deaerator/feed water tank where the
condensate is heated and deaerated for further use as boiler feeding water.
Plant Water System
Main Circulating Cooling Water System
The closed cooling tower system is adopted in this project and 3 sets circulating
water pumps(02 in operation and 01 in standby) are installed for 15MW unit.
Demineralization Plant
A central water treatment plant shall be provided to supply demineralized water. All
required makeup water for the boiler house deaerator is provided by the
Demineralized Water Plant.
The demineralization plant capacity is about 15 t/h. DM plant applied with one stage
of R/O with one stage mixed bed exchanger which will meet the requirement of the
power plant.
FECTO Cement LimitedMake Up Water System
FECTO Cement LimitedType of coal to be used
The Plant will be using bituminous coal with heating value around 4000 – 5000
Kcal/kg local coal and 5800/6700 Kcal/Kg imported coal. Coal blend of local and
imported coal would be used in this project with maximum inherent sulphur as 3 %.
Coal transfer to storage at plant site
The coal will be delivered to the coal yard designed for storage coal volume for 21
days operation with closed shed with designed coal piled 6 meters in height and total
storage volume of app. 6800 ton.
Water Sprinkling System
The coal yard is equipped with water sprinkling system (pipes with nozzles).The coal
is transferred to the crushing plant through two grab cranes installed inside the shed
at the height of coal receiving hopper equipped with bag filter for dedusting during
unloading.
Coal Feeding From Live Stockpile to Coal Bins
One reclaimer conveyor supplies adequate coal to the coal bin via a crushing plant.
The crushing plant supplies coal of suitable size as required by the CFB boiler. The
boiler adopts coal and limestone weigh feeders for feeding measured quantity of fuel
for burning.
FECTO Cement LimitedFecto Cement Limited has been doing their utmost efforts to follow the best
environmental standards since cement plant commissioning. To achieve the minimum
emissions level Fecto Cement Limited had installed high maintenance cost Bag
houses instead of conventional electrostatic precipitators making Fecto cement the
only plant in Pakistan adopting this design.
Plant Layout
Cement Plant Emission Levels
EMISSION LEVELS
AS PER PAKISTAN
STANDARDS
EMISSION LEVELS
OF FECTO
CEMENT LIMITED
PARTICULATE EMISSIONS < 300 mg/Nm3 < 50 mg/Nm3
NOx < 1200 mg/Nm3 < 200 mg/Nm3
SOx < 1700 mg/Nm3 < 220 mg/Nm3
CO < 10 µg/m3 < 6 µg/m3
CO2 - < 65 µg/m3
EXHAUST TEMPERATURE < 90oC
Environmental Protection Measures for the Project
FECTO Cement LimitedSimilarly for 15MW Coal Fired Power Plant special attention has been given to keep
the emissions to minimum level. The technology suppliers/designers and fabricators
enjoy international reputation in emissions control. The plant will be designed in a
way that all sort of emissions from them meet the required levels of the NEQS
Pakistan.
Noise Levels
Since most of the machinery will be placed within the built up area thus ensuring
noise level compliance with in the required standards. Wherever necessary, double
housing to the rattling parts of the machinery, is to be provided for reduction of noise
levels. This is to be incorporated at the design stage of the plant. The maximum noise
levels will not increase from 75 dB(A) during day time and 65 dB(A) during night time
thus will remain in compliance with the limits of the NEQS Pakistan.
Boiler Stack Emissions
Boiler stack emissions of concern are primarily nitrogen oxides (NOx), carbon
monoxide (CO) and particulate matter (PM) and sulphur dioxide SO2. Since CO
emissions are a function of plant operations such as the level of excess air and
maintenance of combustion temperature and residence time, therefore, its
concentrations can be easily controlled while controlling these factors. The following
value of exhaust gasses and PM will be obtained while the power plant is in normal
operation.
FECTO Cement LimitedGases Emission Data
Local Coal Imported Coal
CO: 2~3 mg/Nm3 CO: 1 mg/Nm3
SO2: < 500 mg/Nm3 SO2: < 400 mg/Nm3
NOx: 300 ~ 400 mg/Nm3 NOX: 200 ~ 300 mg/Nm3
PM: 100~150 mg/Nm3 PM: 80~100 mg/Nm3
Ash Handling
Slag ash and fly ash will be produced at the rate of 68 T/day and 29 T/day
respectively. Fly ash handling system and Bottom ash /slag handling system will be
installed. The Chemical Composition of slag and Fly ash is virtually the same as raw
material for cement manufacturing; therefore, the whole quantity will be used in the
cement process.
SOx Emissions
The range of options for the control of SOx emissions is wide because of large
differences in the sulphur content of different fuels and in control costs. In general the
following controls will need to be considered for the respective fuel types.
Less Than 1 % Sulfur:
For low sulfur, high calorific fuels, specific controls may not be required.
1-3 % Sulfur:
For medium sulfur fuels, coal cleaning (when applicable), sorbent injection, or
fluidized bed combustion may be adequate.
FECTO Cement LimitedGreater Than 3 % Sulfur:
For high sulfur fuels, Flue gas Desulfurization Units (FGDs) or other clean coal
technologies should be considered.
After the plant startup, SO2 emissions will be in 300~400 mg/Nm3 when imported coal
is used as fuel and will be < 500 mg/Nm3 when local coal is used as fuel as against
the NEQS Pakistan permissible limiting value of 1700 mg/Nm3.
NOx emissions
After the plant startup, NOx emissions will be 200~300 mg/Nm3 when imported coal is
used as fuel and will be 300~400 mg/Nm3when local coal is used as fuel against the
NEQS Pakistan permissible limiting value of 1200 mg/Nm3.
Particulate Matter (PM) emissions
Particulate matter emissions will be 80~100 mg/Nm3 when imported coal is used as
fuel and will be 100~150 mg/Nm3 when local coal is used as fuel. These values are
well within the prescribed limits of 500.0mg/Nm3 by National Environmental Quality
Standards (NEQS)-Pakistan.
Effluents
About 3 T/hour waste water mainly from power plant process, floor washings, plant
washings and sewage; will be generated. Effluent will be treated with in the existing
operational waste water treatment plant of the Fecto cement. Treated effluent will be
used for irrigation of vegetation, trees and plants and for sprinkling on the roads
within the project boundaries.
FECTO Cement LimitedThe effluents will be treated to the levels as desired by the NEQS Pakistan.
Accordingly, the treatment will achieve the following values of the parameters as
applicable to the power plants:
Sr. No. Parameter Status Mg/l NEQS Limits Mg/l
1 Temperature Not to Increase >3oC of
the recipient water body
Not to Increase >3oC
2 Ph 6-9 6-9
3 Total Suspended Solids 25-30 150
4 Total Residual Chlorine 0.1-0.15 1.0
5 Chromium (Total) 0.2-0.3 1.0
6 Copper 0.2-0.3 1.0
7 Iron 0.5-0.7 2.0
8 Zinc 0.3-0.4 5.0
9 BODs 40-45 80.0
10 COD 60-70 150.0
11 Oil & Grease 4-5 10.0
12 Total Dissolved Solids 450-500 3500.0
FECTO Cement LimitedSince the quality of the treated effluent is to remain within the NEQS limits hence it
will not have any detrimental effect on the environment or human health.
Fire Fighting System
The plant fire fighting system will be designed and installed as per international
standards
1. Coal yard is equipped with water sprinkling system to control the dust during
coal handling.
2. In the boiler coal bin is equipped with temperature sensors and sockets for
N2 inertization in case of high temperatures in the bin.
Health and Safety While Handling Coal
All workforce to be engaged in the coal handling operations, will be wearing
necessary Personal Protective Equipment as mandatory requirement. The massive
coal handling area on the plant site will be restricted for unwanted workers in order to
avoid exposure to the coal for protection against Health Hazards.
Rain Harvesting
For the conservation of water all the buildings will be designed for the latest
techniques of rain harvesting from roofs, floors, trenches and pits etc.
FECTO Cement LimitedFlue Gas Desulfurization System (Absorption Type)
The Flue Gas Desulfurization System selected for the project is of the latest
technology i.e. Absorption Type.
DS Multi-phase reactor is consisting of several absorption units, and in each
absorption unit it has rotary internal components. The mixed flue gas and absorption
liquid will flow into DS Multi-phase reactor from the top, and these forces the mixed
flue gas and absorption liquid turning the speed and direction continuously.
Absorption liquid turns into liquid film affected by the rotary components from the
center to the side symmetrically. Then inside tower wall gather the absorption liquid
into the next absorption unit. One by one, the liquid turns into liquid film and drops
and full fill the reactor. And after full access of the flue gas and absorption liquid, SO2
in flue gas has been absorbed.
Chemical Reaction Principle
Limestone-gypsum flue gas desulfurization process includes absorption, dissolution,
neutralization, oxidation, crystallization etc., its principle is summarized as follows.
Absorption:
SO2(g)→SO2(l)+1/2O2→H++HSO3
−→2H++SO3−
Sulphur dioxide present in Flue Gases absorbs in water under oxidized conditions
which converts into proton and Sulphur Trioxide Ions.
FECTO Cement LimitedDissolution:
CaCO3(s)+ H+→Ca+2+HCO3−
Calcium Carbonate in the presence of protons converts into Calcium Ions and
Bicarbonate Ions.
Neutralization:
HCO3− + H+→CO2(g)+H2O
During neutralization Bicarbonate Ions captures protons to evolve Carbon dioxide and
produce water.
Oxidation:
HSO3−+1/2O2→SO3+H2O
SO3+1/2O2 →SO4
−2
Bisulphite Ions produced in Absorption reaction, reacts with Oxygen to produce
Sulpher Trioxide. Which again reacts with Oxygen to produce Sulphate Ions within
the reaction.
Crystallization:
Ca+2 + SO4-2 + 2H2O→CaSO4.2H2O(s)
Calcium Ions produced during Dissolution and Sulphate Ions produced during
Oxidation reaction reacts with each other in the presence of water to produce
Calcium Sulphate (Gypsum) Dihyderated as a by product of Desulpherisation.
This flue gas desulphurization device is equipped with forced system.
FECTO Cement LimitedDS Multi-Phase Reactor for Flue Gas Desulfurization
FECTO Cement LimitedTypical Flue Gas Desulfurization Process
FECTO Cement Limited
FECTO Cement LimitedKeeping in view the international future squeezing trends in emission control we are
assuming that the existing NEQS (Pakistan) standards will also be revised, Fecto
Cement Limited adopted the most advanced technology of Flue Gas Desulphurization
System i.e. absorption type FGDS with control emissions in the range 200~300
mg/Nm3 (Both for SOx and NOx ).
Thank You