第 5 部 . 添付資料
9. EQUIPMENT DESIGN PHILOSOPHY & INFORMATION
9.3 Induced Draft Fan
●
10% oversizing will be specified.
●
Electrical motor drivers will be specified.
●
Installation of induced draft fan will be unsheltered, outdoor.
FORM 1005-1 CHK’D T. Kayukawa
APP’D M. Morita
REV. DATE PAGE DESCRIPTION PREP’D CHK’D APP’D 2017/7/21 All For Discussion (DRAFT) MH TK MM 2017/8/15 All Data provided by TATA Power MH HI TK DIST’N
CLIENT H.OFFICE
FIELD JGC
CP Instrument
Electrical Civil Piping Equipment Process
T&I PJ FIELD
TATA Power Co., Ltd.
DeSOx & NOx System for Coal-fired Power Plant
A 0
4
Design Basis for Feasibility Study of
DeSOx & DeNOx System at Maithon Power Plant
FORM 1005-2 3
Contents
1. Introduction ... 3 2. Plant Capacity for Commercial Plant ... 3 3. Specifications of Feedstock and Product ... 3 4. Catalyst Characteristics ... 3 Attachment-1 ... 4 Attachment-2 ... 7
FORM 1005-2 3
1. Introduction
JGC’s DeSOx & DeNOx system is the combination of the flue gas desulfurization (FGD) with dry type adsorbent and the selective catalytic reduction (SCR) of NOx with honeycomb type catalyst.
In order to apply this system to high content of dust in flue gas, pretreatment with dust removal unit is also combined to the system. This system can be applied for treatment of any kinds of flue gas from industrial facilities, e.g. power plant, coke oven or cement kiln. The treated gas satisfies environmental regulations.
This document presents fundamental information regarding the basis for the process design of the DeSOx & DeNOx System in a commercial plant.
2. Plant Capacity for Commercial Plant
Capacity 525 MW subcritical, Coal Consumption 293.48 T/hr, Indian Coal Air Consumption 1,824.73 T/hr
Gas Flow Rate 2,342,569 Nm3/hr (at stack inlet) Plant location Maithon, Dombhuin Village
Turn Down 60% (55% as per new regulation)~100%
DeNOx Catalyst Life 2 years
3. Specifications of Feedstock and Product
Attachement-1 defines the specifications of feedstock and product.
4. Catalyst Characteristics
Attachment-2 contains the information on the catalyst for DeNOx unit. An MSDS (Material Safety Data Sheet) will be issued at the time of catalyst delivery.
FORM 1005-2 3
Attachment-1
Specifications of Feedstock and Product
A) Feedstock Specifications A-1. Fuel (Coal)
The information of design coal is required to check flue gas composition for the study. The following items are typical one, but not limited to them.
No. Particulars Units Design
1.0 PROXIMATE ANALYSIS By Weight
1.1 Moisture (Total) % 7.11
1.2 Ash % 36.19
1.3 Fixed Carbon % 40.78
1.4 Volatile Matter % 15.92
1.5 Total % 100
1.6 Gross Calorific Value kcal/kg 4671
2.0 ULTIMATE ANALYSIS
2.1 Carbon % 47.85
2.2 Hydrogen % 2.89
2.3 Sulphur % 0.39
2.4 Nitrogen % 1.00
2.5 Moisture % 7.11
2.6 Ash % 36.19
2.7 Oxygen (by difference) % 4.58
2.8 Total % 100
3.0 Hard Groove Index 50
4.0 Ash Fusion Range
4.1 Initial Deformation Temp. °C
4.2. Hemispherical Temp. °C
4.3 Fusion Temp. °C To be confirmed
A-2. Ash
The following information is based on the analytical results of an ash sample, named as “MPL (Maithon Power Limited)”. “MPL” ash was selected as design case.
No. Particulars Units Design
(MPL)
FORM 1005-2 3
5.0 Chemical Composition
5.1 Silica (SiO2) % 56.11
5.2 Alumina (Al2O3) % 29.96
5.3 Iron oxides (Fe2O3) % 6.00
5.4 Titania (TiO2) % 2.62
5.5 Potassium oxide (K2O) % 1.83
5.6 Lime (CaO) % 1.31
5.7 Phosphoric Anhydride (P2O5) 0.84
5.8 Magnesia (MgO) % 0.48
5.9 Sulphuric Anhydride (SO3) % 0.23
5.10 Sodium oxide (Na2O) % 0.11
5.11 Balance Alkalis (by difference) % 0.50 6.0 Particle Size Distribution
6.1 D10 μm 7.74
6.2 D50 μm 23.33
6.3 D90 μm 111.02
6.4 Detail distribution (Attach-1B)
7.0 Density
7.1 True density (Pycnometer) g/ml 2.25
7.2 Apparent density (close pore included) g/ml 0.64
A-3. Flue Gas (Maithon Power Plant)
No. Particulars Units Design
8.0 Gas Condition
8.1 Location Outlet of
Economizer
Outlet of ESP
8.2 Total Gas Flow Rate (wet)(TMCR)
kg/hr 2,050,000 2,200,000
8.3 T/h 2,050 2,200
8.4 Gas Temp. (TMCR) °C 322 114
8.5 Gas Pressure (TMCR) mmH2OG -60 -276
8.6 Gas viscosity cP Not available Not available
8.7 Gas density kg/Nm3 0.875 0.939
9.0 Flue Gas Composition
9.1 Oxygen vol %-wet
9.2 vol %-dry 3.56 8.7
9.3 H2O vol %-wet
9.4 CO2 vol %-dry 15.43 10.7
9.5 NOx kg/hr 2,062 1,119
FORM 1005-2 3
9.6 mg/Nm3
-dry
@6%O2
880 (100%TGMCR) 477.5
(100%TGMCR)
9.7 NO2 kg/hr 300 163
9.8 mg/Nm3
-dry
@6%O2
128 (assumed as NO2 mol/NO mol = 1/9)
70 (assumed as NO2
mol/NO mol = 1/9)
9.9 SOX kg/hr 1,931 1,687
9.10 mg/Nm3
-dry
@6%O2
824 (Design Coal TGMCR)
720 (Design Coal TGMCR)
9.11 Dust kg/hr 117,129 84
9.12 mg/Nm3
-dry
@6%O2
50,000
(100%SGMCR)
35.85
(100%SGMCR)
B) Product Specification
B-1. Emissions Norm required for the Existing Plant
Permissive level: SO2 200 mg/Nm3 (for > 500MW), NOx 300 mg/Nm3, SPM 50 mg/Nm3
B-2. Treated Gas (Commercial Plant)
Treated gas shall satisfies specifications notified by Ministry of Environment, Forest and Climate Change on 7th December, 2015.
No. Particulars Units Design Coal
12.0 Gas Condition
12.1 Location Outlet of SCR
12.2 Gas Pressure mmH2OG By Contractor
13.0 Treated Gas Composition
13.1 NOx mg/Nm3-dry
@ 6%O2
< 100
13.2 SOx mg/Nm3-dry
@ 6%O2
< 100
13.3 Dust mg/Nm3-dry
@ 6%O2
< 30
13.4 Leak Ammonia ppm < 5
FORM 1005-2 3
Attachment-2
SCR Catalyst Characteristics Including Chemical and Physical Properties
A) Catalyst Name NRU-5
B) Manufacturer JGC Catalysts and Chemicals Ltd.
C) Application & Process SCR
D) Chemical Properties
Active component V2O5
Support carrier TiO2-WO3
E) Physical Properties
Form Honeycomb type, 35cell x 35 cell (typical) Approx. bulk density 0.5 ton/m3
FORM 1005-1 CHK’D H.Isobe
APP’D T.Kayukawa
REV. DATE PAGE DESCRIPTION PREP’D CHK’D APP’D 2017-07-21 All For Discussion (DRAFT) MH TK MM 2017-08-15 All Data provided by TATA Power MH HI TK 1 2017-11-02 All For quotation MH HI TK DIST’N
CLIENT H.OFFICE
FIELD JGC
CP Instrument
Electrical Civil Piping Equipment Process
T&I PJ FIELD
TATA Power Co., Ltd.
DeSOx & NOx System for Coal-fired Power Plant
A 0
4
Design Basis for Basic Design of Demonstration Plant of
DeSOx & DeNOx System at Jojobera Power Plant
FORM 1005-2 3
Contents
1. Introduction ... 3 2. Plant Capacity for Commercial Plant (for Reference) ... 3 3. Plant Capacity and Inlet Condition for Demonstration Unit ... 3 4. Specifications of Feedstock and Product ... 3 5. Catalyst Characteristics ... 3 Attachment-1 ... 4 Attachment-2 ... 8
FORM 1005-2 3
1. Introduction
JGC’s DeSOx & DeNOx system is the combination of the flue gas desulfurization (FGD) with dry type adsorbent and the selective catalytic reduction (SCR) of NOx with honeycomb type catalyst.
In order to apply this system to high content of dust in flue gas, pretreatment with dust removal unit is also combined to the system. This system can be applied for treatment of any kinds of flue gas from industrial facilities, e.g. power plant, coke oven or cement kiln. The treated gas satisfies environmental regulations.
This document presents fundamental information regarding the basis for the process design of the DeSOx & DeNOx System in a commercial plant and a demonstration unit.
2. Plant Capacity for Commercial Plant (for Reference)
Capacity 120 MW subcritical Coal Consumption 70 T/hr, Indian Coal Air Consumption 442 T/hr
Gas Flow Rate 457,999 Nm3/hr
Plant location Tata Power Co. Ltd, Jojobera Power Plant Unit 5, Jamshedpur.
Turn Down 100%
DeNOx Catalyst Life 2 years
3. Plant Capacity and Inlet Condition for Demonstration Unit
Plant location Jojobera Power Plant Unit 5, Jharkhand, India Gas Flow Rate 5,000 Nm3/hr
Gas composition SOx 800 mg/Nm3-dry@ 6%O2
NOx 600 mg/Nm3-dry@ 6%O2
Dust 100 g/Nm3-dry@ 6%O2
DeNOx Catalyst Life 1 year
4. Specifications of Feedstock and Product
Attachement-1 defines the specifications of feedstock and product.
5. Catalyst Characteristics
Attachment-2 contains the information on the catalyst for DeNOx unit. An MSDS (Material Safety Data Sheet) will be issued at the time of catalyst delivery.
FORM 1005-2 3
Attachment-1
Specifications of Feedstock and Product
A) Feedstock Specifications A-1. Fuel (Coal)
The information of design coal is required to check flue gas composition for the study. The following items are typical one, but not limited to them.
No. Particulars Units Design
1.0 PROXIMATE ANALYSIS By Weight C7 July 2017
1.1 Moisture (Total) % 5.28
1.2 Ash % 39.40
1.3 Fixed Carbon % 36.19
1.4 Volatile Matter % 19.13
1.5 Total % 100.0
1.6 Gross Calorific Value kcal/kg 4,281.77 2.0 ULTIMATE ANALYSIS
2.1 Carbon % 49.30
2.2 Hydrogen % 3.32
2.3 Sulphur % 0.43
2.4 Nitrogen % 1.03
2.5 Moisture % 0.00
2.6 Ash % 41.37
2.7 Oxygen (by difference) % 4.55
2.8 Total % 100.0
3.0 Hard Groove Index 65
4.0 Ash Fusion Range
4.1 Initial Deformation Temp. °C >1,332
4.2. Hemispherical Temp. °C >1,332
4.3 Fusion Temp. °C >1,332
A-2. Ash
The following information is based on the analytical results of 2 kinds of ash samples, named as “Jojobera” and “MPL (Maithon Power Limited)”. “MPL” ash was selected as design case since the particle size of “MPL” ash is smaller than that of “Jojobera”, and it should be safer to design dust removal unit.
FORM 1005-2 3
No. Particulars Units Reference
(Jojobera)
Design (MPL) 5.0 Chemical Composition
5.1 Silica (SiO2) % 57.60 56.11
5.2 Alumina (Al2O3) % 28.80 29.96
5.3 Iron oxides (Fe2O3) % 5.87 6.00
5.4 Titania (TiO2) % 1.59 2.62
5.5 Potassium oxide (K2O) % 1.67 1.83
5.6 Lime (CaO) % 1.14 1.31
5.7 Phosphoric Anhydride (P2O5) 0.74 0.84
5.8 Magnesia (MgO) % 0.61 0.48
5.9 Sulphuric Anhydride (SO3) % 0.15 0.23
5.10 Sodium oxide (Na2O) % 1.30 0.11
5.11 Balance Alkalies (by difference) % 0.53 0.50
6.0 Particle Size Distribution
6.1 D10 μm 8.92 7.74
6.2 D50 μm 28.94 23.33
6.3 D90 μm 102.43 111.02
6.4 Detail distribution (Attach-1A) (Attach-1B)
7.0 Density
7.1 True density (Pycnometer) g/ml 2.25
7.2 Apparent density (close pore included) g/ml 0.64
A-3. Flue Gas (Jojobera Power Plant Unit 5)
No. Particulars Units Design 8.0 Gas Condition
8.1 Location Outlet of
Economizer
Outlet of Air Heater
Outlet of ESP 8.2 Total Gas Flow
Rate (wet)
kg/hr Not available Not available 600,610
8.3 Nm3/h Not available Not available 457,999
8.4 Gas Temp. °C 314/310 145/140 129/124
8.5 Gas Pressure mmwc -15.37 Not available -220/ -217 8.6 Gas viscosity cP Not available Not available Not available 8.7 Gas density kg/Nm3 Not available Not available 1.31
9.0 Flue Gas Composition
9.1 Oxygen vol
%-wet
4.1/4.5 6.47/6.6 4.61
9.2 vol %-dry 5.09
FORM 1005-2 3
9.3 H2O vol
%-wet
9.32
9.4 CO2 vol
%-wet
14.5/14.6 11.5/12.6 13.06
9.5 NOx kg/hr 290
9.6 mg/Nm3
-dry
@6%O2
655
9.7 NO2 kg/hr 30
9.8 mg/Nm3
-dry
@6%O2
65
9.9 SOx kg/hr 540
9.10 mg/Nm3
-dry
@6%O2
1225
9.11 Dust kg/hr 45.8
9.12 g/Nm3
-dry
@6%O2
0.1
B) Product Specification
B-1. Emissions Norm required for the Existing Plant
Permissive level: SO2 600 mg/Nm3, NOx 300 mg/Nm3, SPM 50 mg/Nm3
B-2. Treated Gas (Demonstration Unit)
Treated gas shall satisfies specifications notified by Ministry of Environment, Forest and Climate Change on 7th December, 2015.
No. Particulars Units Design Coal
14.0 Gas Condition
14.1 Location Outlet of Demonstration Unit
14.2 Gas Pressure mmH2OG -150
15.0 Treated Gas Composition (Note 1)
15.1 NOx mg/Nm3-dry
@ 6%O2
< 100
15.2 SOx mg/Nm3-dry
@ 6%O2
< 100
15.3 Dust mg/Nm3-dry < 30
FORM 1005-2 3
@ 6%O2
15.4 Leak Ammonia ppm < 5
Note1 : The treated gas composition shall be achieved for the inlet gas composition defined in the Section 3.
FORM 1005-2 3
Attachment-2
SCR Catalyst Characteristics Including Chemical and Physical Properties
A) Catalyst Name NRU-5
B) Manufacturer JGC Catalysts and Chemicals Ltd.
C) Application & Process SCR
D) Chemical Properties
Active component V2O5
Support carrier TiO2-WO3
E) Physical Properties
Form Honeycomb type, 35cell x 35 cell (typical) Approx. bulk density 0.5 ton/m3
F
E
D
C
B
A
8 7 6 5 4 3 2 1
F
E
D
C
B
A
S. Kameda JOB CODE
NO. DATE DESCRIPTIONS PREPDCHKDAPPD
REVISIONS
PREP’D CHK’D APP’D
DWG. NO.
B
DATE： SCALE None
SIZE REV.
TATA Power Co., Ltd.
Process Flow Diagram for DeSOx unit Commercial Plant - Case 1
T. Kayukawa 0 7 7 4 5
H. Isobe
0 2017-10-XX
2017-10-XX
0 For preliminary study S.K H.I T.K
0 2
D-1223-101
0 0 0 0
DRAFT
(NOTE1) FROM ELECTROSTATIC
PRECIPITATOR(EXISTING)
WC INV
FLUE GAS B/L
WC INV
V-101B Z-102A
Z-103A
Z-102B
Z-103B Z-104A
Z-104B
V-102A
NOTE2
101
102A
102B 103B 103A
104
NOTE2
M
M
M
2. SPENT AGENT IS RECYCLED AS PART OF FRESH DESULFURIZING AGENT, OR SOLD TO CUSTOMER, OR DISPOSED FOR LANDFILL.
3. TYPICAL FOR EACH DeSOx TOWER.
C-101B
LSL LSM
INV M M M M
M M M M
C-101C
NOTE 3
C-101A
M M
M M
C-101D
LSL LSM
INV M M M M
M M
M M
C-101F
NOTE 3
C-101E
M M
M M
V-102B
M
V-101A
TO STACK (EXISTING)
B/L
101 102A/B 103A/B 104
Flue gas from existing plant
DeSOx unit inlet gas
DeSOx unit outlet gas
DeSOx unit outlet gas (total)
Vapor Vapor Vapor Vapor
℃ 145 145 130 130
KPaG -2.3 -2.3 -3.8 -3.8
Nm3/h 230,000,000 115,000,000 115,000,000 230,000,000
SOx mg/Nm3 800 800 100 100
NOx mg/Nm3 300 300 300 300
mg/Nm3 50 50 50 50
Stream No.
Fluid Phase
Concentration Dust Temperature
Pressure Flow rate
F
E
D
C
B
A
8 7 6 5 4 3 2 1
F
E
D
C
B
A
S. Kameda JOB CODE
NO. DATE DESCRIPTIONS PREPDCHKDAPPD
REVISIONS
PREP’D CHK’D APP’D
DWG. NO.
B
DATE： SCALE None
SIZE REV.
TATA Power Co., Ltd.
Process Flow Diagram for DeSOx unit Commercial Plant - Case 3
T. Kayukawa 0 7 7 4 5
H. Isobe
0 2017-10-XX
2017-10-XX
0 For preliminary study S.K H.I T.K
0 2
D-1223-102
0 0 0 0
DRAFT
(NOTE1)
TO DeNOx UNIT
FROM ECONOMIZER (EXISTING)
FLUE GAS
D-1223-301
WC INV
FLUE GAS B/L
WC INV
V-102B
C-101B
V-101B V-101A
Z-102A
Z-103A
Z-102B
Z-103B Z-104A
Z-104B
V-102A
NOTE2
M
S-101A H S-102A H
101
102A
102B
103B
103A 104
LSL LSM
INV LSL LSM
INV
LAND FILL
V-103
Z-105
TO ATM AT SAFETY LOCATION
M M M M M M M M
M M M M
M M M M
NOTE2
M M M M M M
M M
M M M M
M M M M M M
M M
M M M M
M
M
M
2. SPENT AGENT IS RECYCLED AS PART OF FRESH DESULFURIZING AGENT, OR SOLD TO CUSTOMER, OR DISPOSED FOR LANDFILL.
C-101C C-101D
C-101F C-101G C-101H
M
NOTE 3
3. TYPICAL FOR EACH DeSOx TOWER.
NOTE 3
101 102A/B 103A/B 104
Flue gas from existing plant
DeSOx unit inlet gas
DeSOx unit outlet gas
DeSOx unit outlet gas (total)
Vapor Vapor Vapor Vapor
℃ 310 310 280 280
KPaG -0.2 -2.2 -3.7 -3.7
Flow rate Nm3/h 230,000,000 115,000,000 115,000,000 230,000,000
SOx mg/Nm3 800 800 100 100
NOx mg/Nm3 600 600 600 600
mg/Nm3 100,000 1,000 30 30
Stream No.
Fluid Phase
Concentration Dust Temperature
Pressure
S-103
C-101A
M M
M M
M M
M M
C-101E
F
E
D
C
B
A
8 7 6 5 4 3 2 1
F
E
D
C
B
A
S. Kameda/M. Hatayama JOB CODE
NO. DATE DESCRIPTIONS PREPDCHKDAPPD
REVISIONS
PREP’D CHK’D APP’D
DWG. NO.
B
DATE： SCALE None
SIZE REV.
TATA Power Co., Ltd.
Process Flow Diagram for DeNOx unit (Commercial Plant Case-3)
T. Kayukawa 0 7 7 4 5
H. Isobe
0 2017-10-XX
2017-10-XX
0 For preliminary study S.K/M.H H.I T.K
0 2
D-1223-301
0 0 0 0
DRAFT
FROM DeSOx UNIT FLUE GAS
R-301
M
301
303
304
M-301
D-1223-102
B/L TREATED FLUE GAS
TO AIR HEATER
DUST COLLECTION
SHALL BE UPDATED BASED ON VENDOR INFORMATION DURING DETAIL ENGINEERING.
302
Z-301
PA
IW
ｖ v v v
FC
TO GRADE
NH3（VAPOR）
NH3（LIQUID）
BY VENDOR BY CONTRACTOR
O2 AI
Z-302
NOTE1
E
TS LS
301 302 303 304
Flue Gas_Main NH3 + Air SCR inlet gas SCR outlet gas
Vapor Vapor Vapor Vapor
℃ 280 20 272 277
KPaG -3.7 15 -4.1 -6
kmol/hr 102,679 3,197 105,876 105,887
Nm3/h 2,300,000 71,612 2,371,612 2,371,876
SOx mg/Nm3 100 0 97 97
NOx mg/Nm3 600 0 582 97
mg/Nm3 30 0 30 30
Concentration Dust Flow rate
Stream No.
Fluid Phase Temperature
Pressure
NOx SOx O2 NH3
AI
Technical and Cost Comparison Report on Dry-DeSOx and DeNOx System
for TATA power
March 2018
Agency for Natural Resources and Energy, Ministry of Economy, Trade and Industry
JGC CORPORATION
FORM 1005-2 3
Contents
Part-I. Outline of Study
1. Executive Summary ... 4 2. Abbreviation ... 4 3. Introduction ... 5 3.1 Project Background ... 5 3.2 Study Objectives ... 5 4. Design Basis ... 5
Part-II. Technical and Economic Study
5. Technology ... 6 5.1 Dry DeSOx Process ... 6 5.2 DeNOx Process ... 8 6. Technical and Economic Study for Commercial Plant ... 9 6.1 Study Case ... 9 6.2 Basic Design Information for Case 1 ... 11 6.2.1 PFD ... 11 6.2.2 Major Equipment ... 11 6.2.3 Required Area ... 12 6.2.4 Effluent ... 13 6.3 Basic Design Information for Case 2 ... 13 6.4 Basic Design Information for Case3 ... 14 6.4.1 PFD ... 14 6.4.2 Major Equipment ... 14 6.4.3 Required Area ... 16 6.4.4 Effluent ... 17 6.4.5 Comparison of Dust Removal System... 17 6.4.5.1 Comparison ... 17 6.4.5.2 Short Summary ... 20 6.5 Economic Study ... 20 6.5.1 Conditions ... 20 6.5.2 Economic Study for Case 1 ... 22 6.5.3 Economic Study for Case 3 ... 24 6.5.3.1 DeSOx System including Dust Removal System ... 24 6.5.3.2 DeNOx System ... 26 6.5.3.3 Overall system (DeSOx system + DeNOx system)... 27 6.5.4 Short Summary ... 30 7. Technical and Cost Information for Demonstration Plant ... 31 7.1 Basic Design Information ... 31 7.1.1 BFD ... 31 7.1.2 Tie-ins to / from the Existing Plant ... 32 7.1.3 PDP ... 32 7.1.4 Major Equipment ... 33 7.1.5 Required Area ... 33 7.1.6 Consumption of Utility, Catalyst and Chemical ... 34
FORM 1005-2 3
7.1.7 Effluents ... 35 7.1.8 Detailed Engineering ... 35 7.2 Schedule ... 36 8. Detail Information of DeNOx Catalyst ... 38 8.1 Analysis of Indian coal ash ... 38 8.2 Influence of Catalyst Poisoning Components on Performance of DeNOx Catalyst ... 41 8.3 Influence of Dust on Erosion of DeNOx Catalyst ... 42 8.4 Design information of DeNOx catalyst ... 44
Part-III. Survey Results of New Environmental Norms
9. Outline of New Environmental Norms and Status ... 46 9.1 Background of Energy Sector in India ... 46 9.2 Outline of New Environmental Norms ... 48 9.3 Present Status of TPPs and Corresponding Status to New Environmental Norms ... 49 9.3.1 Coal Properties Survey ... 49 9.3.2 Flue Gas Properties Survey ... 52 9.3.3 Corresponding Status for New Environmental Norms ... 53
9.3.3.1 Corresponding Status for New Environmental Norms ... 54 9.3.3.2 Corresponding Status with Respective Items ... 54 9.4 Challenges in Complying with New Environmental Norms ... 56 9.4.1 Challenges in Complying with SOx norms ... 56 9.4.2 Challenges in Complying with NOx norms ... 58 9.4.3 Challenge Level in Complying the New Environmental Norms ... 59 9.5 Latest Situation of Interactions about New Environmental Norms ... 61 9.5.1 Present situation for New Environmental Norms ... 61 9.5.2 Short Summary ... 63
Part-IV. Survey Results of Market
10. Market Information ... 64 10.1 Market Survey of DeSOx and DeNOx system ... 64 10.1.1 Category (a): Installation of DeSOx and DeNOx system to New TPPs ... 65 10.1.2 Category (b) and (c): Retrofit of Existing TPPs ... 70 10.2 Requirement for DeSOx and DeNOx system ... 72 10.2.1 Requirement for DeSOx system ... 72 10.2.2 Requirement for DeNOx system ... 74 10.3 DeSOx and DeNOx Suppliers in India and Their Activities ... 75 10.4 Properties and Market of Raw Materials for Dry Desulfurizing Agent ... 77 11. Conclusions and Recommendations ... 80
Part-V. Attachment
Attachment List ... 81
FORM 1005-2 3
1. Executive Summary
This document presents the results of a feasibility study and technical information regarding the introduction of the dry DeSOx process and DeNOx process into coal-fired thermal power plants owned by TATA Power Co., Ltd. in India. In addition, commercial and market information associated with the dry DeSOx process and DeNOx process is included.
2. Abbreviation
The following abbreviations are used in this document:
A/H : Air Heater
BFD : Block Flow Diagram CAPEX : Capital Expenditure
CAGR : Compound Annual Growth Rate CEA : Central Electricity Authority CF : Capacity Factor
CFD : Computation Fluid Dynamics COP : Conference of the Parties DeSOx : Desulfurization DeNOx : Denitrification ECO : Economizer
ESP : Electrostatic Precipitator FGD : Flue Gas Desulfurization GCV : Gross Calorific Value GGH : Gas/Gas Heat Exchanger
INDC : Intended Nationally Determined Contributions MC : Multicyclone Separator
METI : Japanese Ministry of Economy, Trade of Industry OPEX : Operating Expenditure
PDP : Process Design Package PFD : Process Flow Diagram
P&ID : Piping and Instrument Diagram PLF : Plant Load Factor
RE : Renewable Energy
SCR : Selective Catalytic Reduction SNCR : Selective Non-Catalytic Reduction SPM : Suspended Particulate Matter TPP : Thermal Power Plant
TPS : Thermal Power Station
FORM 1005-2 3
3. Introduction
3.1 Project Background
Associated with rapid economic growth, environmental norms are tightening in India, and the Ministry of Environment, Forest and Climate Change (MoEF&CC) published the New Environmental Norms (hereinafter called “the Norms”), 2015 for thermal power plants (TPP) to amend the Environment (Protection) Rule, 1986 (refer to Table 9-1 and Table 9-2). Under these circumstances, JGC, JGC C&C, SOJITZ and JCOAL organized a consortium, with the financial assistance of the Japanese Ministry of Economy, Trade of Industry (METI), in order to meet the needs for flue gas treatment in coal-fired TPP by exporting the exclusive dry DeSOx process and DeNOx process.
3.2 Study Objectives
The main objective of this study is to confirm the feasibility of introducing the dry DeSOx process and DeNOx process into coal-fired TPP in India. For this purpose, the competitiveness of the dry DeSOx process and DeNOx process over the conventional wet DeSOx process and DeNOx process was be assessed from technical and commercial aspects.
4. Design Basis
This feasibility study was conducted based on several conditions confirmed with TATA Power Co., Ltd. Those conditions (such as coal analysis data, flue gas compositions and conditions, etc.) are specified in the following documents in Attachments 1, 2 and 3.
- Basic Engineering Design Information S-1222-001 - Design Basis for Maithon Power Plant S-1222-101 - Design Basis for Jojobera Power Plant S-1222-102
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5. Technology
5.1 Dry DeSOx Process
The dry DeSOx process (i.e., dry-FGD process) was developed by Hokkaido Electric Power Co., Inc. in Japan in the late 1980’s and applied to its own coal-fired TPP. The TPP is operating commercially from 1991 up to the present date. In addition, the dry DeSOx process was applied for treating the flue gas from coke oven in China in the past 2~3 years and those plants are operating up to the present date without any major troubles.
The dry-DeSOx process uses a desulfurizing agent to absorb sulfur dioxide (SO2) and convert it to calcium sulfate (CaSO4) through a DeSOx tower. The DeSOx tower comprises two stages of moving beds with the desulfurizing agent, which is supplied from the top and discharged to the bottom hopper zone (refer to Figure 5-1). The flue gas is fed to the lower stage and contacted with the desulfurizing agent by cross flow. In this stage, in addition to absorbing sulfur dioxide (SO2), the remaining dust is trapped by the desulfurizing agent. The flue gas is exit from the lower stage and fed to the upper stage. In this stage, the flue gas is contacted with fresh desulfurizing agent by cross flow and sulfur dioxide (SO2) is absorbed to the desulfurizing agent, again. Then, the SOx concentration in the flue gas achieves to the target value.
Figure 5-1 DeSOx Tower
The desulfurizing agent is a mixture of calcium hydroxide (Ca(OH)2), coal ash, and calcium sulfate (CaSO4). The chemical reaction is represented by the following equation:
2Ca(OH)2 + 2SO2 + O2 → 2CaSO4 + 2H2O ‐(1)
The desulfurizing agent is pelletized, as shown in Figure 5-2. The desulfurizing agent is produced by the process scheme shown in Figure 5-3.
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During the hydrothermal treatment, calcium silicate is produced and it contributes to absorption of sulfur dioxide (SO2). Part of the spent desulfurizing agent is recycled as raw material to replace of calcium sulfate (CaSO4), since spent the desulfurizing agent consists mainly of calcium sulfate (CaSO4). Typical schematic drawing of production of desulfurizing agent is shown in Figure 5-4.
Figure 5-4 Schematic Drawing of Desulfurizing Agent Production Figure 5-2 Desulfurizing Agent
Figure 5-3 Process Scheme for Production of Desulfurizing Agent
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5.2 DeNOx Process
DeNOx process uses selective catalytic reduction (SCR) for nitrification. As a gaseous reductant, air-diluted ammonia (NH3) vapor is injected upstream of the catalyst. The chemical reaction is indicated by the Equations (2), (3) and (4). Nitric oxide (NO) and nitrogen oxide (NO2) are converted to nitrogen (N2) and water (H2O).
4NO + 4NH3+O2 → 4N2 + 6H2O ‐(2) NO + NO2 + 2NH3 → 2N2 + 3H2O ‐(3) NO2 + 8NH3 → 7N2 + 12H2O ‐(4)
In general, plate type or honeycomb structured catalyst is used. Honeycomb structured catalyst provides higher performance, as the required volume of catalyst is smaller than that of the plate type. Honeycomb structured catalyst can be used for clean flue gas (dust free or low concentration of dust) as plugging from a high concentration of dust is not anticipated.
Figure 5-5 Honeycomb Structured Catalyst
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6. Technical and Economic Study for Commercial Plant
6.1 Study Case
The technical and economic study was conducted by assuming that the dry-DeSOx process and DeNOx process are introduced into a new or existing TPP, which is equivalent to 1 unit (525 MW, flue gas flow rate 2,300,000 Nm3/h) of the Maithon power plant in the Jharkhand state in India. The study was made for the following three cases and the details of each case are described hereafter:
Case 1: Retrofit of dry-DeSOx system and low NOx burner into the existing plant Case 2: Retrofit of dry-DeSOx system and DeNOx system into the existing plant Case 3: Installation of dry-DeSOx system and DeNOx system into the new plant
The configuration of existing plant was assumed as shown in Figure 6-1. The configuration is the same as that of the Maithon power plant.
Figure 6-1 Configuration of Existing Plant
In Case 1, the exiting plant will be retrofit with the dry-DeSOx system and low NOx burner.
NOx concentration is decreased to the Norms’ level (refer to Table 9-1) or lower by installing the low NOx burner into the existing boiler. SOx concentration is decreased to the Norms’ level or lower by installing the dry-DeSOx system downstream of ESP. The configuration and process conditions of Case 1 are shown in Figure 6-2.
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Figure 6-2 Configuration and Process Conditions of Case 1
In Case 2, the existing plant will be retrofit with the dry-DeSOx system and DeNOx system.
SOx concentration is decreased to the Norms’ level by installing dry-DeSOx system downstream of ESP. NOx concentration is decreased to the Norms’ level by installing DeNOx system downstream of dry-DeSOx system. The configuration and process conditions of Case 2 are shown in Figure 6-3.
Figure 6-3 Configuration and Process Conditions of Case 2
In Case 3, the dry-DeSOx system and DeNOx system will be installed in a new plant. SOx concentration is decreased to the Norms’ level by installing dry-DeSOx system downstream of the dust collection system. NOx concentration is decreased to the Norms’ level by installing DeNOx system downstream of the dry DeSOx system. The configuration and process conditions of Case 3 are shown in Figure 6-4.
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Figure 6-4 Configuration and Process Conditions of Case 3
6.2 Basic Design Information for Case 1 6.2.1 PFD
PFD for Case1 is shown in Attachment-4. Flue gas from the existing ESP is introduced to DeSOx Tower (C-101A~F) and SOx is absorbed by the desulfurizing agent by contacting with the desulfurizing agent in the DeSOx Tower (C-101A~F). The treated flue gas is discharged from the existing stack to atmosphere. The desulfurizing agent is stocked in Fresh Agent Hopper (V-101A/B), weight-measured by Fresh Agent Weigh Scale (Z-102A/B) and then fed to the DeSOx Tower (C-101A~F) by Fresh Agent Conveyer (Z-103A/B). The spent desulfurizing agent is used at a rate of 7.45 ton/hr and discharged from the bottom of DeSOx Tower (C-101A~F) and transferred to Spent Agent Hopper (V-102A/B) by Spent Agent Conveyer (Z-104A/B). In addition to this DeSOx system, desulfurizing agent production facility (refer to Figure 5-4) is installed separately.
6.2.2 Major Equipment
Conceptual drawing of one unit of DeSOx Tower is shown in Figure 6-5 and Figure 6-6. DeSOx Tower (C-101A~F) comprises 4 beds/tower × 3 towers/unit ×2 units. The dimensions are 19.6 m long ×14.0 m wide × 32.0 m high per unit.