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Air Pollution Control and Environmental Solutions
By Alok ChandVice President . Boldrocchi India
Air Pollution Control Business
INTRODUCTION – BOLDROCCHI AT A GLANCE
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More than 100 years of experience in design, engineering,supply, erection & commissioning
Product range includes fans, blowers, compressors, heatexchangers, coolers, gas turbine systems, noise protectionsystems, heavy duty diverters, dampers
More than 88000 orders executed worldwide
State of the art technology for air pollution control: Dust removal Organic micro pollutants removal Gaseous acids removal Vaporized metals removal Sulphur and nitrogen oxides removal
INTRODUCTION – BOLDROCCHI AT A GLANCE
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Solutions offered by Boldrocchi for Air Pollution Control
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Solutions offered by Boldrocchi for Air Pollution Control
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Solutions offered by Boldrocchi for Air Pollution Control
This presentation highlights the technologyand solutions provided by Boldrocchi forcleaning of flue gases arising out of variousindustrial processes.
As a case study, flue gas cleaning systemfor waste to energy plants and biomassplants has been illustrated in thispresentation.
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Dry sorbent injection system (hydrated lime)(also sodium bicarbonate injection system is being applied)
Activated Carbon injection system Dry Reactor (with or without recirculation of reagents) Water injection system with zero liquid discharge DeSox Reactor Bag filter based cleaning DeNox with SCR/ SNCR DeNox with combined SCR and SNCR
Above solutions are applicable also for steel, power, cementand other allied industries and Boldrocchi has severalreferences for the same.
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Technology and Systems adopted for case study:
Rapid technological development over the last few years
Stringent norms for pollution control necessitating reliabletechnology for reduced emissions
Huge potential in India - accelerated by Government of India under“Swach Bharat Mission” (Clean India Mission)
Five running plants in India Many others under construction Numerous others in planning stage About 200 WTE plants to come up in next 3-5 years
Non uniform quality of waste particularly in India (high moisture)
Typical configuration of waste to energy plants in India
Waste treatment capacity of 450-2000 T of waste per day 4 to 30 MW of electrical power generation by combining one or more
than one boilers
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Waste to Energy Sector at a glance:
TYPICAL SECTIONS IN WASTE TO ENERGY PLANTS
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Flue Gas Treatment System
Processo IndustrialeFonte di Emissioni
Waste Combustion
DUST
SO2
HCL
HF
NOx
Heavy Metals
Carbon compounds
Hg, Cd, Tl, As, Ni, Pb
CO2, CO, hydrocarbons (VOCs), PCDD/F
Key environmental issues in waste to energy and biomass plants
In fully oxidative incineration the main constituents of the flue-gas are water vapor, nitrogen, carbon dioxide and oxygen. Depending on the composition of the material incinerated and on the operating conditions, the main emissions are:
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Flowsheet of a FGCSO
UT
ECO
NO
MIZ
ER
PRIMARY DEDUSTING
CYCLONE, ESP OR BAG FILTER
GAS TEMPERATURE REGULATION
BASIC REAGENTS STORAGE
ADSORBENT STORAGE
(ACTIV.CARBON)
PREPARATION; TRANSPORT;
DOSING
CONTACT REACTOR REAGENTS-FLUE GAS
BAG FILTER
DUST TRANSPORT SYSTEM
FILTER PREHEATER AND ACCESSORIES
FINAL GAS EXTRACTION FAN + STACK
HEAT EXCHANGERDeNOx REACTOR
DUST STORAGE
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• High SO2 Removal Efficiency– Up to 99% removal
• Flexible– Multi-Pollutant Removal
• SO2, SO3, HCl, Hf, Dioxins, Furans• Hg Removal• Up to 50% NOx removal
– Fuel & process flexibility– Works in High Moisture Applications
• Low Capital & Operation Cost– Modular fabrication– Simplicity of design with small footprint– No slurry systems– Exotic Alloys not required– Low pressure drop– High recycle rate low reagent consumption – Significantly reduced maintenance and operation
cost compared to Spray Dryers and Wet Scrubbers
Salient Features of Boldrocchi’s DeSox
Complete Flue Gas Cleaning Plant
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Reaction Tower
Bag house
Typical Arrangement - Example
Waste Silo
Reagent Silo
Salient Features of Boldrocchi’s DeSox / DeNox system
SCR reactor
Case Study-2 – Waste to Energy Power Plants in India (Municipal Waste based)
Case Study-1 - Biomass based power plant at Europe(Cereal straw & wood based)
Following case studies have been illustrated in this presentation
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Case Study-1 - Biomass based power plant (Cereal straw & wood based)
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General Plant Overview
Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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Project Background - Pollutants
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Reference FuelConfigurations 100 %
straw
55 % straw
45 % woodchips (40 %
H2O)
55 % straw
45 % woodchips (50 %
H2O)
Flue gas flowrate (Nm3/h) 100.817 109.936 114.030
Flue gas temperature at
boiler outlet (oC)139 143 143
Ash in the flue gas at boiler
outlet (g/Nm3 dry)
5,34 4,50 4,60
Flue gas composition (ash absent)
CO2 (% in mass) 20,30750 19,70684 19,52255
H2O (% in mass) 9,18136 11,28013 12,17492
SO2 (% in mass) 0,02956 0,02582 0,02589
N2 (% in mass) 65,70962 64,37260 63,70338
O2 (% in mass) 4,63258 4,52699 4,48117
HCl (% in mass) 0,13938 0,08762 0,09209
NOx (mg/Nm3 at 6 % of O2) 250-300 250-300 250-300
CO (mg/Nm3 at 6 % of O2) 100 100 100
Modality of combustion:
Combustion 100 % straw
Combustion of straw and woodchips (max 35 % on energy basis)
Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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Project Background - Emission Limits
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Pollutant present
in the flue gas
(mg/Nm3)
Emission limits on the basis of
Authorization of the DPR
13/03/2013 n.58 (daily mean)
Emission limits on the basis of the
DLgs 152/2006, ref. NTP > 50 MW
(daily/hourly mean)
Emission limits on the
basis of the DM 06-07-
2012 (monthly mean)
Ash 5 30/- 5
CO 100 200/100 50
TOC 10 20/10 10
NOx 100 400/200 100
NH3 10 - 5
SOx 100 200/- 25
HCl 10 - 10
HF 1 - -
Mean values of the emission limits imposed by the Authority.Reference: 11 % of oxigen (O2), dry gas, normal condition of 1013 mbar and 0 °C.
Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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Configuration of the FGCS
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Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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NOx abatement systems
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NOx Abatement
SNCR
SCR
SNCR + SCR
Principal reactions for nitrogen oxides (NOx) reduction through ammonia injection:
4 NO + 4 NH3 + O2 → 4 N2 + 6 H2O
2 NO2 + 4 NH3 + O2 → 3 N2 + 6 H2O
The most flexible solution
Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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SNCR
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Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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The ammonia solution is directly injected in the boiler(last part of the evaporator) by means of two levels oflances (each level consists of four lances).
Upstream the injection system (lances), a dosing skid isnecessary to obtain the required amount of ammoniasolution in terms of water content (dilution) and pressure.
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Acid gases, dioxins and furans abatement
(SOx HCl e HF)
Dry Reactor (with or without dust
recirculation)
Bag Filter "Secondary Reactor"(thickness of the “cake”)
Principal reactions for acid gases abatement (SOx HCl e HF) through lime injection:
Ca(OH)2 + 2 HCl → CaCl2 + 2 H2O
Ca(OH)2 + 2 HF → CaF2 + 2 H2O
Ca(OH)2 + SO2 → CaSO3 + H2O
Ca(OH)2 + SO3 → CaSO4 + H2O
Dosing Lime
Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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Dry reactor is positined downstream theboiler and upstream the bag filter.
Two storage silos (160 m3 each)equipped with vibrators and pneumatictransport system for reactor feeding.
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Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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The activated carbon, stocked in "big bags", are opportunelydosed and sent to the dry reactor (with the lime) by means of apneumatic transport system.
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Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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Two storage silos (250 m3 each)equipped with vibrators and electricalheaters.
Each silo consists of a telescopic dischargesystem for truck.
SCR – Ammonia Storage
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Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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Ammonia tank = 40 m3 (SS) Protected by a containment
structure. Safety relief valve on top of tank
to prevent ammonia dispersion. Common ammonia tank for both
SNCR and SCR. Safety system for unloading by
truck.
SCR Reactor
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Case Study 1 - Biomass power plant at Europe (Cereal straw & wood)
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Two honeycomb structure reactors toincrease catalytic surface.
Placed downstream the bag filter (topreserve the catalytic surfaces).
Two heat exchanger (gas/gas andgas/steam) to mantain a constanttemperature (SCR inlet) of about 250°C (ideal for SCR).
• The ammonia solution is injected in astatic mixing chamber (upstream theSCR and downstream the HEs) bymeans of four lances.
Case Study-2 – Municipal waste based power plants in India
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Parameters Unit InletInlet Temp Deg C Max 180-240Gas Flow NM3/Hr 125,000 – 200,000Water vapour % 23 - 25HCl mg/Nm3 Up-to 1500SO2 mg/Nm3 1000-1200CO mg/Nm3 50-100TOC mg/Nm3 20HF mg/Nm3 10Dioxins & Furans ngTEQ/Nm3 10Cd + Th + other compounds mg/Nm3 0.52Hg and its compunds mg/Nm3 0.07Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V + their compunds
mg/Nm3 8.9
Total dust load mg/Nm3 6000-10000
Waste Treatment capacity: 450 - 2000 TPDPower Generation: 4 - 30 MW
Case Study-2 – Municipal Waste based Power Plant in India
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Characteristics of flue gas at inlet of FGCS (at 12% O2 on dry basis)
Typical configuration:
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Clean Flue Gas
Process Gas
Fresh Reagent
Recycle Loop
Flue Gas with Entrained Reagent
BaghouseReaction
Tower
Air Slide Conveyor
Reagent Silo
Spent Reagent to Waste
DP SOx
P
Water
T
Technology Applied
Case Study-2 – Municipal Waste based Power Plant in India
Paramter Unit Inlet OutletHCl mg/Nm3 1500 10-20SO2 mg/Nm3 1000-1200 50-100CO mg/Nm3 50-100 <50TOC mg/Nm3 20 <10HF mg/Nm3 10 4Dioxins & Furans ngTEQ/Nm3 10 0.1Cd + Th + other compounds mg/Nm3 0.52 0.05Hg and its compunds mg/Nm3 0.07 0.05Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V+ their compunds
mg/Nm3 8.9 0.5
Total dust load mg/Nm3 6000-10000 10
All above values corrected to 12% Oxygen on a dry basis
Flue gas requirement at outlet
Boldrocchi India is in the process of building 5 such flue gas treatment plants in India.
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Case Study-2 – Municipal Waste based Power Plant in India
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Reaction Tower - Characteristics
• Straight vessel without moving parts• Multi-Venturi design for large gas flows• Reagent recirculation above the venturis• Tower bottom waste discharge • Inlet vanes for proper gas distribution• Flue gas recirculation loop
Case Study-2 – Municipal Waste based Power Plant in India
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Water Injection System - Features
• Air atomized / spill back lances• Redundant High pressure multistage
centrifugal pumps• Options of air atomized lance & spillback
return lance• Multiple lances for large gas flows• Design margin for temperature excursion• High turndown ratio• Barrier air to prevent lance clogging
Case Study-2 – Municipal Waste based Power Plant in India
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Hydrated Lime Storage & Dosing System
• Pneumatic conveying from site hydration unit or truck
• Gravimetric dosing of hydrated lime to scrubber
• Loss-in-Weight (LIW) reagent feeding system by pneumatic conveying from hydrated lime silo to scrubber
• Two (2) LIW units for each reaction tower for redundancy and metering accuracy
• Flow enhancing device for trouble free flow
Case Study-2 – Municipal Waste based Power Plant in India
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Reagent recycle & waste disposal features
• Recycle hopper with airslides• Fluidization air supplied by PD
blowers• Diverter valve for disposal of
by-product• Reagent surge bin• Pneumatic conveying from Re-
circulation hoppers to Waste silo
Case Study-2 – Municipal Waste based Power Plant in India
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Fabric Filter Features• Long bags (up-to 10 mts long). Longer
bags ensure smaller foot print area• Intermediate pressure cleaning air
(3-4 bar)• Gas and dust distribution distribution
defined by CFD analysis, physical models and experience
• Cross flow design, promoting- More efficient cleaning- Levelised reagent recirculation - Reduced wear compared to conventional
hopper entry designs
Case Study-2 – Municipal Waste based Power Plant in India
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Other References
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Other References
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Other References
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Other References
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Boldrocchi - Complete solution for flue gas cleaning
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Boldrocchi - Complete solution for flue gas cleaning
Thank you for your attention
Boldrocchi India Pvt Ltd1801, 1802, 1907, Tower 4, DLF Corporate Greens, Sector 74-A, Gurgaon-122004T. +91 8961562592, E-mail: [email protected]