FY2019 Indian FGD Commissioning & Performance Test requirements - - PowerPoint PPT Presentation

CEA-JCOAL Workshop FY2019

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Indian FGD – Commissioning & Performance Test requirements at Coal-fired Power plants

Chugai Technos Corporation, Japan

Company Network Profile

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Established : 1953 Employees : 983 Branches : 20

Hiroshima (Head Off.) Fukuoka Kobe Tokyo & Chiba Fukushima

Established : 2014 Employees : 20

Ho Chi Minh

Vietnam Japan

India Planning for 2020

Bangalore

Environmental Business Division Industrial Engineering Business Division Structural E Engineering Business Division Electronic System B Business Division Measurement Instrument Information Business Division

Environ ironmen ental tal invest estiga igati tion

• n and analys

ysis is / environ ronme menta tal consulta tant Machin ine design ign and produ ducti tion

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facilit ity constr truction ction Thermal conductiv ctivit ity y & hydrody rodynami mics cs testi ting g and measurem rement CAE(Comp

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ter Aided d Engineerin ering) g) design ign / Structu cture res and materia rial stre rength gth invest estiga igati tion

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Non-de destr tructiv ctive testi ting g / Concre rete te deteriora iorati tion

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invest estiga igati tion

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Facilit ities control rol design ign / mainte tenance

Chugai-Technos Business Divisions Industrial Technology Division

Business Division

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Chem emica cal en enginee eering involved ed i in flue e gas trea eatmen ent

Unit Operation

Solid Catalytic reaction, Dust Collection / Classification,

Gypsum

Flow, heat transfer / evaporation, humidity control, stirring / mixing Gas absorption, gas-liquid contact operation, crystallization, filtration Drying, distillation, adsorption / ion exchange, membrane separation, coagulation / sedimentation / filtration

Rol

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• f

f Chu hugai in n Che hemical En Engine neering ng

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• 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.

－ Flow of the plant construction －

Performance test

• 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.

Performance Test

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Standard Methods : ASME PTC-40 Guidelines : FGD Manufactures (Technical Specifications)

a

• Percentage

ge removal of SO SO2

b

• Stoichi

hiom

• met

etric ic ratio particul ulat ate e emission

c

• Energ

rgy/Po /Powe wer r consum umpt ptio ion

d

• Water ch

characteri eriza zation ion

e

• Reagent

t consumpt ption ion / Ch Characteriz izati tion

• n

f

• Waste & By-produ
• duct productio

tion n and characte teriz izati tion

• n

High Perfomance Monitoring System 5 conponets analyzer (NOX, SO2, CO, CO2, O2) Site Analysis Leak Ammonia Analysis Inlet & Outlet Duct Long Size Pitot Tube for Flow Rate Measurement Dust Concentration CO2, O2 and N2 Measurement by Orsat Leak Ammonia at SCR System Sampling Unit Environmental Measurement at Stack Confirmation of Test Process in the Central Control Result Report

PG Test – Air Monitoring Sampling with expertise Methods US EPA, EPRI, ASTM & JIS Reports delivered as per standard procedures

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8 Glass Dust holder Sampling Probe 4m Length SO3 Sampler NOX Sampler

Moisture Sampler

SO2 Sampler

Mist Moisture Sampler

Dust holders

Sampling Equipment Special probes for specific parameters Inbuilt technology for SO3 monitoring Mist Eliminator – Mist exhaust level checking

Example of large FGD duct at coal power plant

9 From ESP

To Stack

Outlet B-1 Inlet B-1 Inlet B-2 Outlet B-2 Inlet A-2 Inlet A-1 Outlet A-1 Outlet A-2 B-FGD A-FGD

Area 12.96 ㎡ Area 13.52 ㎡ ＜ＥＰOutlet＞ ＜ＥＰInlet＞ 3600 450 900 900 900 450 １× ２× ３× ４× × × × × × × × × × × × × 3600 ｄ c b a 520 1040 1040 1040 1040 １× ２× ３× ４× ５× × × × × × × × × × × c b a 2600 5200 520 low flow

<FGD Inlet> <FGD Outlet>

flow

Performance Test Sampling

Engineer Engineer Engineer

INLET Minimum 4 engineers will be required. 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

Engineer

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Vertical Duct Monitoring

Area 12.96 ㎡ Area 13.52 ㎡ ＜ＥＰOutlet＞ ＜ＥＰInlet＞ 3600 450 900 900 900 450 １× ２× ３× ４× × × × × × × × × × × × × 3600 ｄ c b a 520 1040 1040 1040 1040 １× ２× ３× ４× ５× × × × × × × × × × × c b a 2600 5200 520 low flow

＜OUT UTLET ET ＞ ＜INLET＞

10 M 16 M

Addit ition ional Flange ge

Engineer Engineer Engineer Engineer Engineer Engineer Assistance

Assis ista tance

Totally 5 Engineers are required One Japanese Engineer : Complete management & Gas meter adjustment. Two Technical Engineer : Sampling at traverse points Two Assistance : : Supporting Technical Engineer

Engineer

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Horizontal Duct Monitoring

Samples involved

• Flue gas (Inlet & Outlet)
• Lime stone
• Lime stone slurry
• Re-circulation slurry
• Gypsum
• Water & Waste water
• Re-circulation water

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FGD Operational issues

• Poor SO2% removal
• Poor Chemical reagent utilization
• Limestone blinding
• Poor Gypsum quality
• Scaling
• Mist eliminator pluggage
• Mist exhaust from stack

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Regular chemical process monitoring required in O&M activity

Mist Size check : Mist Eliminator

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Chugai`s Method : MgO Plated sheet sampling ME - Inlet ME - Outlet Mist size : Min. 0~20µm to Max. 500µm 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.

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Thank you very much for your kind attention

http://www.chugai-tec.com/

• B. Sarangaraja (b.sarang@chugai-tec.co.jp)