CEA-JCOAL Workshop FY2019 Indian FGD – Commissioning & Performance Test requirements at Coal-fired Power plants Chugai Technos Corporation, Japan 1
Company Network Profile India Japan Vietnam Fukushima Hiroshima Kobe (Head Off.) Tokyo & Ho Chi Minh Chiba Fukuoka Established : 2014 Bangalore Employees : 20 Established : 1953 Planning for 2020 Employees : 983 Branches : 20 2
Business Division Environmental Business Division Environ ironmen ental tal invest estiga igati tion on and analys ysis is / environ ronme menta tal consulta tant Industrial Engineering Business Division CAE(Comp omputer ter Aided d Engineerin ering) g) design ign / Structu cture res and materia rial stre rength gth invest estiga igati tion ons Structural E Engineering Business Division Chugai-Technos Non-de destr tructiv ctive testi ting g / Concre rete te deteriora iorati tion on Business invest estiga igati tion on Divisions Electronic System B Business Division Machin ine design ign and produ ducti tion on / facilit ity constr truction ction Measurement Instrument Information Business Division Facilit ities control rol design ign / mainte tenance Industrial Technology Division Thermal conductiv ctivit ity y & hydrody rodynami mics cs testi ting g and measurem rement 3
Chem emica cal en enginee eering involved ed i in flue e gas trea eatmen ent Gypsum Unit Operation Drying, distillation, Flow, heat transfer / adsorption / ion evaporation, humidity control, Solid Catalytic reaction, exchange, membrane stirring / mixing Gas absorption, Dust Collection / separation, coagulation / gas-liquid contact operation, Classification, sedimentation / filtration crystallization, filtration 4
Rol ole o of f Chu hugai in n Che hemical En Engine neering ng － Flow of the plant construction － Performance test 1. Role in Commissioning Test Adjustments are required in different Units; finalization of adjustments are verified by out come of chemical testing. Usually these process carried out for 3 months in commissioning. 2. Role in Performance Test Third party confirmation & MoU with FGD makers to final guarantee of unit operation. Usually these process carried out for 10 days in commissioning. 5
Performance Test Standard Methods : ASME PTC-40 Guidelines : FGD Manufactures (Technical Specifications) • Percentage ge removal of SO SO 2 a • Stoichi hiom omet etric ic ratio particul ulat ate e emission b • Energ rgy/Po /Powe wer r consum umpt ptio ion c • Water ch characteri eriza zation ion d • Reagent t consumpt ption ion / Ch Characteriz izati tion on e • Waste & By-produ oduct productio tion n and characte teriz izati tion on f 6
Leak Ammonia at SCR System Dust Concentration Inlet & Outlet Duct Long Size Pitot Tube for Flow Rate Measurement PG Test – Air Monitoring Sampling with expertise CO 2 , O 2 and N 2 Measurement by Sampling Unit Orsat Methods US EPA, EPRI, ASTM & JIS Reports delivered as per standard Environmental procedures Measurement at Stack High Perfomance Monitoring System 5 conponets analyzer (NO X , SO 2 , CO, CO 2 , O 2 ) Leak Ammonia Analysis Confirmation of Test Process in the Result Report Site Analysis Central Control 7
Dust holders Glass Dust holder Sampling Equipment Special probes for specific parameters Inbuilt technology for SO 3 monitoring Mist Eliminator – Mist exhaust level checking Sampling Probe 4m Length SO 2 Sampler SO 3 Sampler NO X Sampler Mist Moisture Sampler Moisture Sampler 8
Performance Test Sampling Example of large FGD duct at coal power plant <FGD Outlet> <FGD Inlet> ＜ＥＰ Inlet ＞ ＜ＥＰ Outlet ＞ c b a From ESP ｄ c b a 520 １× × × 450 1040 １× × × × Inlet B-2 Inlet A-1 900 ２× × × Inlet B-1 Inlet A-2 ２× × × × 1040 900 3600 5200 ３× × × A-FGD B-FGD ３× × × × Outlet A-1 1040 Outlet B-2 900 ４× × × Outlet B-1 Outlet A-2 ４× × × × 450 1040 3600 ５× × × 520 2600 flow flow low To Stack Area 12.96 ㎡ Area 13.52 ㎡ 9
Vertical Duct Monitoring Engineer Engineer INLET Engineer Minimum 4 engineers will be required. Engineer 2 (Red) well experienced engineers and 2 worker l level. One Japanese Engineer : Complete management & Gas m meter adjustment. One Technical Engineer : Sampling at t traverse points Two Assistance : : Supporting Technical Engineer 10 10
Horizontal Duct Monitoring ＜ OUT UTLET ET ＜ INLET ＞ ＜ＥＰ Outlet ＞ ＜ＥＰ Inlet ＞ ＞ c b a Assistance Totally 5 Engineers Addit ition ional ｄ c b a Flange ge are required 520 １× × × Engineer Engineer 450 One Japanese 1040 １× × × × Engineer : 900 ２× × × Complete Engineer Engineer ２× × × × 1040 management & Gas meter adjustment. 900 3600 16 5200 ３× × × M ３× × × × 1040 Two Technical 900 Engineer : ４× × × Engineer ４× × × × Sampling at 450 1040 Engineer Engineer traverse points 3600 ５× × × 520 Assis ista tance Two Assistance : : 10 2600 Supporting M flow low Technical Engineer Area 12.96 ㎡ Area 13.52 ㎡ 11 11
Samples involved • Flue gas (Inlet & Outlet) • Lime stone • Lime stone slurry • Re-circulation slurry • Gypsum • Water & Waste water • Re-circulation water 12 12
FGD Operational issues • Poor SO 2 % removal • Poor Chemical reagent utilization • Limestone blinding • Poor Gypsum quality • Scaling • Mist eliminator pluggage • Mist exhaust from stack Regular chemical process monitoring required in O&M activity 13 13
Mist Size check : Mist Eliminator Issues in Exhaust Gas from FGD i. Low dispersion of pollutants ii. Visibility of plume after stack emission iii. Liquid droplet rainout from the stack, and iv. Corrosion problems on downstream materials. Chugai`s Method : MgO Plated sheet sampling ME - Inlet ME - Outlet Mist size : Min. 0~20 µm to Max. 500µm 14 14
Thank you very much for your kind attention B. Sarangaraja (b.sarang@chugai-tec.co.jp) http://www.chugai-tec.com/ 15 15
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