KC Cottrell Inc. Brochure

Edition EMB Rev 3A Gas Suspension Absorber Technology for Multi-pollutant Control of Boiler Flue Gas Emissions Gas Suspension Absorber Dust transport Reactor Re-circulation box Tower//Access Nozzle lance Pumps Lime silo Cyclone Dust filter BY-product silo • A recirculating bed dry scrubber technology capable of efficient acid gas control – SO2, HCl, and H2SO4. • Utilizes lime reagent either as dry hydrate or as lime slurry. • Coupled with ESP or FF for control of PM and PM-10 emissions. • Can incorporate ACI for control of Hg and dioxins//furans. • Emissions of HCl, PM, Hg below MACT requirements. Gas Suspension Absorber Technology • Excellent for retrofitting existing plants • Experience with various combustor types • Cyclone captures majority of bed material • Recirculation box returns captured material to bed • Can utilize typical filter or ESP – Not elevated or oversized • Slim footprint • Modularized Approach – Pre-engineered sizes • Can utilize either dry lime injection or lime slurry – Low consumption rates. Unique Features of the GSA Gas Suspension Absorber With dry lime injection 1 Active carbon silo 2 Reactor 3 Cyclone 4 Re circulation box 5 Nozzle lance 6 Pump 7 Water tank 8 Air compressor 9 Blower 10 Ca(OH)2 silo 11 Fabric filter 12 Flue gas 13 Re-circulated sorbent 14 By-product to silo or disposal 1 14 9 2 3 4 5 6 7 8 10 11 12 13 12 6 Elevation Drawing A- Gas Flow Gas pathGas path Gas Suspension Absorber Reactor Lime slurry or water Dual Fluid Nozzle Gas distribution vanes Air lock Recirculated Material • Co-current upflow reactor • Flue gas enters at the bottom and is turned up into the venturi stage. • Dry hydrated lime is pneumatically injected below the venturi. • Water is injected at the periphery of venturi via dual fluid nozzles. • Recirculated material is returned to the reactor above the venturi. • Droplet drying and acid gas removal occur in the reactor. Dry lime injection Flue Gas To Cyclone Gas Suspension Absorber Mass transfer principle in the reactor High particle density. Venturi inlet generates high turbulence. Conditioned sorbent across the full reactor cross section. Recirculated sorbent achieves a high apparent SR. Recirculated material Atomization nozzle Gas Suspension Absorber Dual Fluid Nozzles GSA Nozzle Gas Suspension Absorber Semi-dry system With lime slurry injection 1 Active carbon silo 2 Reactor 3 Cyclone 4 Re-circulation box 5 Nozzle lance 6 Pump or blower 7 Water tank 8 Air compressor 9 Lime slurry 10 Lime silo 11 ESP or FF filter 12 Water inlet 13 Flue gas 14 Re-circulated sorbent 15 By-product 7 1 14 9 2 3 4 5 6 7 8 10 11 13 12 6 6 13 15 Carbon dosage Gas Suspension Absorber Cyclone Heating element Rapping anvil Heating element • Solid particles are transported out of the top of the reactor and into the cyclone(s). • In the cyclone, the majority of the particles are separated from the flue gas and directly returned to the reactor via the re-circulation box(es). • Up to 99% of the particles are captured; only the smaller lighter particles are transferred over to the filter. Principles of GSA//Cyclone Two parallel cyclones From Reactor Gas Suspension Absorber Recirculation Box (1 per cyclone) Sorbent Load cell Double re-circulation screws Butterfly valve Scalping screw Air lock Heating element Butterfly valve • The recirculation box returns material to the reactor via screw conveyors. • A constant level is achieved by extracting by-product residue via the scalping screw. • Material from the scalping conveyor is suitable for pneumatic transport. Scalping Screw Recirculation Screws Gas Suspension Absorber Recirculation Box Gas Suspension Absorber Particulate Collection The flue gas containing residual solids enters the final particulate collector, which can be either a fabric filter or an electrostatic precipitator. The collector chosen depends on the contents of the flue gas and the extent of acid gas cleaning required. Fabric filters are best for high efficiencies because all of the gas must pass through the sorbent bearing dust. Electrostatic Precipitator Fabric Filter Gas path Plot Plan – Gas Flow • Used extensively for power and incineration applications for more than 20 years • Numerous installations in North America, Europe and Asia • Five projects (nine industrial boilers) executed since KC licensed the technology in 2005 Gas Suspension Absorber Experience Gas Suspension Absorber Installations Single GSA Location Multiple GSA Location GSA Applications • Power • Coal - 14 • Oil - 1 • MSW - 20 • HazWaste - 10 • Metals - 2 • Biomass - 3 EUROPE – 28 ASIA – 15 N. AMERICA - 7 Nine Dragons China Pt. Comfort Texas Cheng Loong Taiwan Petron 1&2 Philippines Petron 3&4 Philippines Fuel Coal Petcoke or PRB Coal or Coal + Sludge Coal or Petcoke Coal or Petcoke Flue Gas (per Boiler) 258,188 ACFM x 2 526,194 ACFM x 2 144,403 ACFM 185,545 ACFM x 2 185,545 ACFM x 2 Arrangement 2 Boilers 2 GSA 2 Boilers 4 GSA 1 Boiler 1 GSA 2 Boilers 2 GSA 2 Boilers 2 GSA Operational 2008 2011 2012 2013 2015 Inlet // Outlet SO2 4,000 // 800 ppm 250 // 75 ppm 45 // 34 ppm 630 // 40 ppm 250 //90 ppm 250 //90 ppm Reactor Dimensions 16.6 ft Dia 69 ft Height 14.3 ft Dia 91 ft Height 11.4 ft Dia 51.5 ft Height 11.75 ft Dia 62 ft Height 11.75 ft Dia 62 ft Height KC Cottrell GSA Installations Gas Suspension Absorber Nine Dragons, China Gas Suspension Absorber Point Comfort, TX Gas Suspension Absorber Cheng Loong, Taiwan GSA Under Construction Petron Refinery, Philippines • Two New CFB Boilers (1.1 MM lb//hr each) designed to fire PRB and Pet Coke. – Fuel sulfur content up to 6% • Equipped with Gas Suspension Absorbers and Fabric Filters for emissions control – SO2, Acid gases, PM, Hg • Purchase Order placed in 2007 • Equipment delivered in 2008 • Startup in 2011 The Point Comfort Project Gas Suspension Absorbers Point Comfort, TX • Two Pet coke // PRB Fired Boilers (143 MWe each) • Two trains per boiler: each with GSA//PJFF • Inlet Gas Flow (per GSA): 300,000 ACFM @ 295F • Outlet SO2 = 0.19 lb//MMBtu (pet coke); 0.08 lb//MMBtu (PRB) • Outlet PM = 44 mg//Nm3 (0.03 lb//MMBtu) • Removal Efficiencies: – HCl = 95%, HF = 95%, SAM = 92%, Hg (90+%) • GSA Reactors: 14’ dia. x 91’ ht. • Dry hydrated lime injection for Acid gas control (SO2, HCl, H2SO4.) • Water injection for temperature control & humidification – Three atomizing nozzles per reactor • PAC injection for Hg control • PJFF: 8 compartments, 285 bags – Bags: 6” dia. x 22’ long, PPS Gas Suspension Absorbers Point Comfort, TX • Hydrated lime – One silo per boiler (14.5’ diameter x 30 ft. each) – Equipped with bin activator and table feeder – Pneumatically transported & injected into GSA – Particle size: 95% thru 325 mesh • Water – Plant water quality for cooling – One cylindrical tank per boiler – Redundant supply pumps Reagent Prep and Delivery • Sorbent Injection upstream of PJFF • Current sorbent = Brominated PAC • One system per boiler • Storage silo (7.5’ dia. x 16’ ht. each) • Sorbent pneumatically conveyed to ductwork Mercury Reduction System Gas Suspension Absorber Reference Project : Point Comfort, TX Dry Scrubber, Baghouse Gas Suspension Absorber Point Comfort, TX • Both boilers are at full load – Fire pet coke (6% S), natural gas • GSA systems are on-line and controlling emissions. – Outlet SO2 emissions < 10 ppm @100% pet coke firing – HCl emissions < 0.022 lb//MMBtu – PM emissions < 0.03 lb//MMBtu – Hg emissions < 1 lb//Tbtu Current Status at Point Comfort Chengloong Test Results • Unit in operation for 1 year • SCR + GSA + FF • GSA = 11.5’ dia. x 52’ height • SO2 removal tested at 95-97 % – Design guarantee = 93% • No difference between using dry lime injection vs. lime slurry GSA - Sample Control Screen • Economical • Low outlet emissions of HCl, SO2, PM, Hg • Low reagent usage • Ability to use existing collector (ESP, FF) • Minimal plan area requirement • Modular configuration • Shorter erection period • No internal moving parts Benefits of the GSA Dry Scrubber • Broad Experience • EP or EPC offerings • Global resources • Over 4500 reference installations • Manufacturing Capability • Comprehensive clean air solutions for – Particulate control (PM, PM-10, PM-2.5) – Acid Gas Control (SO2, SO3, HCl, HF) Benefits of Working with KC Cottrell Thank you! Questions? Mike Widico 908-304-2004 mwidico@kccottrell.us