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VGB PowerTech - All rights reserved - Alle Rechte vorbehalten - © 2015 54 Modernisation of Belchatow FGD VGB PowerTech 11 l 2015 Authors Kurzfassung Modernisierung der Rauchgasentschwefelungsanlagen von Block 5 und 6 im Kraftwerk Belchatow Im Jahr 2013 hat RAFAKO S.A. einen Vertrag über die Modernisierung von zwei Rauch- gasentschwefelungsanlagen (REA) im Kraft- werk Belchatow unterzeichnet. Die Moderni- sierung sollte zur Erhöhung des Wirkungsgrads durchgeführt werden. Dazu wurden Siebböden unter den Sprühebenen im Absorber eingebaut. In dem vorliegenden Beitrag werden der Lö- sungsansatz, der Einfluss auf den Wirkungs- grad und die Betriebserfahrungen dargestellt. Durch die Modernisierungsmaßnahmen wird der SO 2 -Abscheidegrad erhöht. Das gilt auch bei der Verbrennung von Brennstoffen minde- rer Qualität und bei schärferen Grenzwerten in neuen sowie bestehenden Absorbern. Modernisation of the flue gas desulphurisation plants of units 5 and 6 at the Belchatow power plant, Poland Jerzy Mazurek and Paulina Molas Dipl.-Ing. Jerzy Mazurek Dipl.-Ing. Paulina Molas RAFAKO S.A., Raciborz, Poland Introduction Belchatow power plant is the largest lig- nite-fired power plant both in Poland and in Europe. The overall capacity of the units operated at the Belchatow site amounts to 5,452 MW: Units 1 and 2 = 360 MW el each, Units 3 to 5 = 380 MW el , each Unit 6 = 394 MW el , Unit 7 to 12 = 390 MW el , each and Unit 14= 858 MW el . The plant capacity roughly equals to about 19 % of the entire Polish installed capac- ity. The annual average energy production is about 33 to 34 TW h , representing ap- proximately 20 % of electricity production in Poland. Currently the Belchatow power plant op- erates thirteen flue gas desulphurisation (FGD) absorbers based on the lime-gyp- sum method. The first FGD plant was put into service in 1994 for unit no. 10 and the last one for units 1 and 2 was taken into op- eration in 2012. The new unit 14 (or A1) with a capacity of 858 MW is equipped with two wet des- ulphurisation absorbers. All units from no. 3 to no. 12 have their separate wet desulphurisation absorbers. Units 1 and 2 are equipped with one common wet scrubber. This is due to the planned de- commissioning of unit no. 1 and planned implementation of co-firing with biomass. At the same time the flue gas ducts system of absorbers for units 4, 3 and 1, 2 is inter- connected thus enabling desulphurisation of flue gas coming from all four boilers, in average flue gas load conditions, by ab- sorber no. 3. Due to: impairment of the fuel combusted pa- rameters (higher sulphur content in coal, Table 1), Tab. 1. Impairment of the fuel combusted parameters (larger sulphur content in coal). Parameter Unit Sulphur content in coal min average max Strip mine Belchatow – year 2000 % mass 0.25 0.75 1.20 Strip mine Szczercow – year 2009 % mass 0.40 1.20 1.85 Tab. 2. Methods of wet desulphurisation plant absorbers effectiveness increasing. Group Method description Features Chemical methods Use of highly pure (>98 %) and highly reactive CaCO 3 Higher sorbent price. Limited sorbent availability Use of CaO instead of CaCO 3 High sorbent price. Change of sorbent suspension unit. Increase of process pH value Possible deposits and build-ups in the absorber. Product (gypsum) quality impairment. Use of inorganic additives (Mg salts) Additional chemical substance. Impairment of wastewater parameters. Use of organic additives (organic acids) Additional chemical substance. Impairment of wastewater parameters. Physical methods Application of finer sus- pension droplets. Replacement of spray levels or spray nozzles. Increase of L/G (spray density). Installation of additional and/or replacement of existing circulation pumps and spray levels. Installation of perforated shelf. Installation of perforated baffle below or within the spray levels.

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Modernisation of Belchatow FGD VGB PowerTech 11 l 2015

Authors

Kurzfassung

Modernisierung der Rauchgasentschwefelungsanlagen von Block 5 und 6 im Kraftwerk Belchatow

Im Jahr 2013 hat RAFAKO S.A. einen Vertrag über die Modernisierung von zwei Rauch-gasentschwefelungsanlagen (REA) im Kraft-werk Belchatow unterzeichnet. Die Moderni-sierung sollte zur Erhöhung des Wirkungsgrads durchgeführt werden. Dazu wurden Siebböden unter den Sprühebenen im Absorber eingebaut. In dem vorliegenden Beitrag werden der Lö-sungsansatz, der Einfluss auf den Wirkungs-grad und die Betriebserfahrungen dargestellt. Durch die Modernisierungsmaßnahmen wird der SO2-Abscheidegrad erhöht. Das gilt auch bei der Verbrennung von Brennstoffen minde-rer Qualität und bei schärferen Grenzwerten in neuen sowie bestehenden Absorbern.

Modernisation of the flue gas desulphurisation plants of units 5 and 6 at the Belchatow power plant, Poland Jerzy Mazurek and Paulina Molas

Dipl.-Ing. Jerzy Mazurek Dipl.-Ing. Paulina Molas RAFAKO S.A., Raciborz, Poland

Introduction

Belchatow power plant is the largest lig-nite-fired power plant both in Poland and in Europe. The overall capacity of the units operated at the Belchatow site amounts to 5,452 MW:

– Units 1 and 2 = 360 MWel each, – Units 3 to 5 = 380 MWel, each – Unit 6 = 394 MWel, – Unit 7 to 12 = 390 MWel, each and – Unit 14= 858 MWel.

The plant capacity roughly equals to about 19 % of the entire Polish installed capac-ity. The annual average energy production is about 33 to 34 TWh, representing ap-proximately 20 % of electricity production in Poland.Currently the Belchatow power plant op-erates thirteen flue gas desulphurisation (FGD) absorbers based on the lime-gyp-sum method. The first FGD plant was put

into service in 1994 for unit no. 10 and the last one for units 1 and 2 was taken into op-eration in 2012.The new unit 14 (or A1) with a capacity of 858 MW is equipped with two wet des-ulphurisation absorbers. All units from no. 3 to no. 12 have their separate wet desulphurisation absorbers. Units 1 and 2 are equipped with one common wet scrubber. This is due to the planned de-commissioning of unit no. 1 and planned implementation of co-firing with biomass. At the same time the flue gas ducts system of absorbers for units 4, 3 and 1, 2 is inter-connected thus enabling desulphurisation of flue gas coming from all four boilers, in average flue gas load conditions, by ab-sorber no. 3.Due to:

– impairment of the fuel combusted pa-rameters (higher sulphur content in coal, Ta b l e   1 ),

Tab. 1. Impairment of the fuel combusted parameters (larger sulphur content in coal).

Parameter Unit Sulphur content in coal

min average max

Strip mine Belchatow – year 2000 % mass 0.25 0.75 1.20

Strip mine Szczercow – year 2009 % mass 0.40 1.20 1.85

Tab. 2. Methods of wet desulphurisation plant absorbers effectiveness increasing.

Group Method description Features

Chemical methods

Use of highly pure (>98 %) and highly reactive CaCO3

Higher sorbent price. Limited sorbent availability

Use of CaO instead of CaCO3 High sorbent price. Change of sorbent suspension unit.

Increase of process pH value Possible deposits and build-ups in the absorber. Product (gypsum) quality impairment.

Use of inorganic additives (Mg salts) Additional chemical substance. Impairment of wastewater parameters.

Use of organic additives (organic acids)

Additional chemical substance. Impairment of wastewater parameters.

Physical methods

Application of finer sus-pension droplets.

Replacement of spray levels or spray nozzles.

Increase of L/G (spray density). Installation of additional and/or replacement of existing circulation pumps and spray levels.

Installation of perforated shelf. Installation of perforated baffle below or within the spray levels.

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Modernisation of Belchatow FGD VGB PowerTech 11 l 2015

– more stringent requirements concerning protection of atmospheric air,

– the end of the operating time of the spe-cific items or equipment installed inside the absorber (rubber, plastic items and mist eliminators)

– improve work efficiency (reducing media consumption, reducing power consump-tion) and improving the operating con-ditions (solutions to reduce the failure rate, solutions to improve access etc.),

the oldest flue gas desulphurisation plants built in the 90s of the last century are to be modernised.

Solutions

Approaches to increase the effectiveness and efficiency of existing absorbers opera-

tion in wet flue gas desulphurisation plants are listed in Ta b l e 2.

Most of the specified methods for increas-ing absorber efficiency were tested in the Belchatow power plant and after con-firming the positive effects, some of these methods were implemented.

Absorber modernisation at the Belchatow power plant results not only resulted in in-creased operational parameters but also in the considerable extension of FGD service life. Therefore, it was planned to include among others the comprehensive replace-ment of anti-corrosion lining (rubber lin-ing) inside the absorbers as well as all re-quired repairs.

Ta b l e 3 shows the construction years of the FGD plants, basic design data as well

as years and methods of their modernis-ation.

F i g u r e s 1 to 3 depict examples of mod-ernisation methods employed for absorb-ers in the Belchatow power plant.

Increased liquid to gas ratio (L/G) – Installation of additional spray levels

During the period from 2006 to 2008 RA-FAKO S.A. modernised the FGD plants of units 8, 10, 11 and 12 related to the planned burning of coal with higher sulphur con-tents originating from the new open pit mine called Szczercow. The primary goal of modernising these was to achieve a des-ulphurisation efficiency exceeding 95  %

Fig. 1-3. 3 methods of modernisation FGD in Belchatow PS: new spray level, perforated shelf, organic acid dosing station.

Tab. 3. Specification of the flue gas desulphurisation systems at the Belchatow power plant.

Unit no 10 8 12 11 6 5 9 7 4 3 14 2* 1*

Power of boiler unit [MWel]: 390 390 390 390 394 380 390 390 380 380 858 360 360

Year of FGD plant commissioning 1994 1995 1996 1996 2000 2000 2003 2003 2007 2007 2011 2012 *

Original design value of SO2 conc. in raw flue gas [mg/m3

STP, dry, 6 % O2]4,130 4,130 4,130 4,130 5,500 5,500 9,750 9,750 9,750 9,750 12,400

6,874 9,750

Original required SO2 emission limit [mg/m3

STP, dry, 6 % O2]400 400 400 400 400 400 400 400 400 400 400

200 400 *

Year of FGD plant modernisation 2008 2007 2008 2008 2008 2013

20142013 2014 – – – – – – *

New design value of SO2 conc. in raw flue gas**) [mg/m3

STP, dry, 6 % O2]9,750 7,750

9,750 7,750

9,750 7,750

9,750 7,750

9,750 7,750

9,750 7,750 – – – – – – *

Absorber/plant modernisation method L/G Ac.

L/G Ac.

L/G Ac.

L/G Ac.

PS Ac.

PS Ac. Ac. Ac. Ac. Ac. *** Ac. *

* flue gas desulphurization plant for units 1 and 2 specified in the table above assigned for unit no. 2 enables cleaning of flue gas coming from both units, 1 and 2, at partial load thereof

** distinguished range only achieved by physical methods and with application of acid*** planned after connection limestone preparation plant with FGD unit 858 MWL/G installation of additional spraying level in the absorberPS installation of overflow perforated shelf with dynamic foam in the absorberAc. construction of one, common for the whole plant organic acids dosing system (formic acid and adipic acid)

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VGB PowerTech 11 l 2015 Modernisation of Belchatow FGD

within the whole range of FGD plant opera-tional load and with planned considerable increase of SO2 concentration in flue gas at FGD inlet.The adopted solution for FGD plants of the units 8, 10, 11 and 12 increased the inten-sity of flue gas spraying through the instal-lation of the additional fifth spray level.

Application of organic acids

The application of organic acids (Ta b l e 4) as process additives deserves special atten-

tion. RAFAKO S.A. has carried out research works focused on the application of formic acid and adipic acid:

– Similar results, i.e., above 100 mg/m3

STP, dry, 6% O2, are achieved when dos-

ing the same concentrations of adipic or formic acid.

– When examining the parameters it was found that formic acid allows achieve-ment of SO2 concentrations at the level of 30 mg/m3 STP, dry, 6% O2, whereas the same value for adipic acid amounts to 50 mg/m3 STP, dry, 6% O2 only.

– The dosage of formic acid is faster visible in the process.

Economic analyses have shown that the dosage of organic acid to obtain the desired outlet SO2 concentration below 120 to 160 mg/m3 STP, dry, 6% O2 results in lower operating costs compared to the increase of the L/G ratio. This comparison concerns the cost of purchase and dosage of acid as well as cost of electric power consumption. For each case such analysis must be carried out on an individual basis because they de-pend on electric power unit prices as well as on FGD plant configuration and operat-ing conditions.

Installation of overflow perforated shelf (PS)

The scope of modernisation of units 5 and 6 included also installation of a perforated shelf system. This decision was made due to the limited space for installation of the additional circulating pump in the pump-ing house, lack of space for installation of the additional spray level inside the ab-sorber and restrictions concerning electric power supply for additional pumps.The principle of the perforated shelf opera-tion may be summarised as follows: sorb-ent suspension flowing from spray level nozzles is distributed to the individual perforated shelf cells where it is contacted with flue gas in counter-current flow thus creating a layer of intensive mixing and mass exchange called the “barbotage” (bubbling) zone.

Fig. 4. Project realization stages modernisation of FGD Units 5 and 6 at the Belchatow power station.

Fig. 5. Design model of perforated shelf in unit no. 5 absorber of at the Belchatow power plant (absorber cross-section).

Tab. 4. Specification of organic acids applied in FGD plants.

Parameter Formic acid Adipic acid

Molecular formula

HCOOH HOOC-(CH2)4-COOH

Form Colourless, clear liquid with acrid, irritating smell

White, odourless solid

Remarks Strongly reducing compound, caustic and inducing corrosion, its vapours are heavier than air, vapours may form explosive mixture with air

Irritating compound

Hazards C – caustic X – irritating

Water solubility

Unlimited: well soluble in water, mixes with water in every ratio

19 g/dm3 at 20 °C

Tab. 5. Advantages of installation the perforated shelf in wet FGD plant absorbers.

Existing absorbers New sbsorbers

1. Considerable improvement of gaseous phase distribution in absorber cross-section.

1. Reduction of L/G ratio.

2. Implementation possible in case of lack of space for additional circulating pumps and spray levels installation.

2. Decreased capacity of absorp-tion suspension circulating pumps and decreased height of spray levels in the absorber.

3. Increase of absorption liquid residence time in absorption zone resulting in absorption of greater SO2 mass stream, i.e. increase of flue gas desulphurisation efficiency without changing the geometric features of the apparatus.

3. Lower costs of foundations, piping and electric equipment.

4. Increased effectiveness of dust, HCl and HF removal from flue gas.

4. Lower electric power consump-tion for FGD system needs when compared with systems based solely on spray levels.

5. The tray may serve as a platform facilitating the inspection of spray levels.

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Modernisation of Belchatow FGD VGB PowerTech 11 l 2015

F i g u r e 4 shows the schedule of modern-ising the FGD for units 5 and 6.

The perforated shelf assures uniform flue gas distribution and elimination of zones with lower desulphurisation efficiency.

The installation of the perforated shelf sys-tem increases several times the residence time in the spray zone, i.e. the contact between sorbent suspension and flue gas, which corresponds in the scope of flue gas desulphurisation efficiency improvement to a considerable increase of absorber height or spray intensity (density).

Ta b l e 5 shows advantages of using the perforated shelf system for construction the new and modernisation of existing absorbers. The design model of the perfo-rated shelf is shown in F i g u r e 5.

Ta b l e 6 presents comparison of param-eters and efficiency of the auxiliary FGD

systems for power units no. 5 and 6 before and after modernisation. F i g u r e 6 and 7 compare gypsum dewatering systems

Fig. 6. Gypsum dewatering system of the FGD unit 5 and 6 before and after modernisation. 2 vacuum band filters with a capacity of 36 t/h each 1 filter covers 66 % of the gypsum production The maximum dewatering capacity: 72 t/h

Fig. 7. Gypsum dewatering system of the FGD unit 5 and 6 before and after modernisation. 12 centrifuges with a capacity of 8.7 t/h each 10 centrifuges covers 100 % of the gypsum production The maximum dewatering capacity: 87 t/h

Tab. 6. Parameters of the FGD unit 5 and 6 before and after modernization.

Parameter Unit Before modernisation

After modernisation

Raw flue gas volume stream mSTP3/h 2,100,000 2,100,000

SO2 concentration in FGD inlet mg/m3STP, dry, 6 % O2 5,500 9,750

SO2 concentration in FGD outlet mg/m3STP, dry, 6 % O2 <400 <200

Guaranteed reduction of SO2 % >93 > 98

Process water consumption m3/h 269.7 376.3

Sorbent consumption t/h 28.7 52.1

Oxidation air consumption t/h 32.4 59.6

Gypsum production tdry/h 48.0 87.3

Product dewatering process – Vacuum filtration Centrifugal filtration

Guaranteed final moisture of product % mass <10 <9

Fig. 8. Comparison of three chosen methods to increase efficiency of wet flue gas desulphurisation absorbers (1 – the worst valuation, 3 – the best valuation).

for FGD no. 5 and 6 before and after mod-ernisation. It should be noted that the new gypsum dewatering system, based on the centrifuges, was fixed in the existing build-ing without changing the exterior walls.

Summary

With available flue gas desulphurisation technique and the application of well-proven solutions, both, the currently appli-cable as well planned emission limits, can be met.Wet FGD bears potentials for modernisa-tion thus increasing SO2 removal effective-ness also in case of increased contaminants concentration at the inlet.At the Belchatow power plant there various methods for improvement of operational output and effectiveness of FGD were suc-cessfully applied:

– increase of L/G ratio with additional in-stallation of spray levels,

– installation of overflow perforated shelf with dynamic foam,

– application of organic acids as process additives.

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VGB PowerTech 11 l 2015 Modernisation of Belchatow FGD

Tab. 7. Comparison of the applied methods to increase the FGD absorber’s efficiency.

Method of modification Advantages Disadvantages

Application of the additional spraying level Full elasticity of operation and possibility of adaptation to the current needs by pump switching on/off.Immediate effect.Comfort of operation (automatic switching on/off).Base for the other methods.

The longest time of erection.The highest capital cost.The lowest cost of operation in steady conditions but at variable loads – especially at lowest loads – ensures the best possibility of operation and operational cost optimization.

Application of perforated shelf Introduces convenient platform for in-spection of spraying levels.No additional chemical medium.

In the absorber it appears increase of pressure drop – highest than in case of the additional spraying level.There may be required modification of the booster fans.

Application of organic acid The lowest cost of operation (in steady conditions, at variable load – not always).The lowest capital cost.

Application of additional chemical me-dium causes specified hazards.Required processes of the new chemical delivery and unloading.Doesn’t ensure elasticity nor fast reaction for changes of load – saturation of the system requires several tons of the medium.

F i g u r e 8 and Ta b l e 7 show assess-ment/comparison of different methods to increase the efficiency of wet flue gas des-ulphurisation absorber used in the Belcha-tow power plant.

Units

Index Example DescriptionSTP mg/m3STP Gas converted into standard conditions m3STP/h for temperature and pressure: 273.15 K;

1013.25 hPa abs.

dry mg/m3STP, dry Dry gas after deduction of the water m3STP, dry/h vapour content

6 % O2 mg/m3STP, dry, 6 % O2 Gas converted for reference content m3STP, dry, 6 % O2/h of O2 = 6 % vol.

References [1] Mlynarski, R., and Jurkowski, J.: Effects of

power-generating units modernization on quality of flue gas desulphurisation processes. PGE Gornictwo i Energetyka Konwencjon-

alna S.A. Oddzial Elektrownia Belchatow, VIth Discussion Forum “Operational expe-rience on FGD plants”, 16 – 19 April 2013, Tatrzanska Lomnica, Slovakia.

[2] Krahl, S., and Mazurek, J.: Selected RAFAKO S.A. research work on wet lime gypsum flue gas desulphurisation method based on the classic spray tower absorbers. Power Gen Conference Papers, Milan 2011.

[3] Mazurek, J., Mlynarski, R., and Jurkowski, J.: Improving Capacity and Efficiency of Power Units No 5 and 6 FGD Absorbers at PGE Belchatow Power Plant, Poland. Power Gen Conference Papers, Cologne 2014.

[4] Mlynarski, R., Jurkowski, J., and Mazurek, J.: Modernizacja Instalacji Odsiarczania Spalin w PGE GiEK S.A. Oddział Elektrownia Bełchatów – doświadczenia eksploatacyjne. VIIth Discussion Forum “Operational expe-rience on FGD plants”, 21 to 24 April 2015, Tatrzanska Lomnica, Slovakia. l

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Market Overview for Imported Coal

In ter na tio nal Jour nalfor Elec tri ci ty and Heat Ge ne ra ti on

Pub li ca ti on ofVGB Po wer Tech e.V.www.vgb.org

Vo lu me 89/2009 · ISSN 1435-3199

K 43600

In ter na tio nal Edi ti on

Focus: VGB Congress

Power Plants 2009

Report on the Activities

of VGB PowerTech

2008/2009

EDF Group Reduces

its Carbon Footprint

Optimising Wind Farm

Maintenance

Concept for Solar

Hybrid Power Plants

Qualifying Power Plant Operators

In ter na tio nal Jour nal

for Elec tri ci ty and Heat Ge ne ra ti on

Pub li ca ti on of

VGB Po wer Tech e.V.

www.vgb.org

Con gress Is sue

Vo lu me 89/2009 · ISSN 1435-3199

K 43600

In ter na tio nal Edi ti on

Focus: Furnaces, Steam Generators and Steam TurbinesUSC 700 °C Power Technology

Ultra-low NOx Combustion

Replacement Strategy of a Superheater StageEconomic Post-combustion Carbon Capture Processes

In ter na tio nal Jour nalfor Elec tri ci ty and Heat Ge ne ra ti onPub li ca ti on ofVGB Po wer Tech e.V.www.vgb.org

Vo lu me 90/2010 · ISSN 1435-3199

K 43600

In ter na tio nal Edi ti on

Fo cus: Pro Quality

The Pro-quality

Approach

Quality in the

Construction

of New Power Plants

Quality Monitoring of

Steam Turbine Sets

Supply of Technical

Documentations

In ter na tio nal Jour nal

for Elec tri ci ty and Heat Ge ne ra ti on

Pub li ca ti on of

VGB Po wer Tech e.V.

www.vgb.org

V

00634 K

9913-5341 NSSI · 5002/58 emulo

International Edition

Schwerpunktthema:

Erneuerbare Energien

Hydrogen Pathways

and Scenarios

Kopswerk II –

Prevailing Conditions

and Design

Arklow Bank

Offshore Wind Park

The EU-Water

Framework Directive

International Journal

for Electricity and Heat Generation

Publication of

VGB PowerTech e.V.

www.vgb.org

Vo lu me 89/2009 · ISSN 1435-3199

K 43600

In ter na tio nal Edi ti on

Focus: Maintenance

of Power Plants

Concepts of

IGCC Power Plants

Assessment of

Generators for

Wind Power Plants

Technical Data for

Power Plants

Oxidation Properties

of Turbine Oils

In ter na tio nal Jour nal

for Elec tri ci ty and Heat Ge ne ra ti on

Pub li ca ti on of

VGB Po wer Tech e.V.

www.vgb.org

Page 8: Modernisation of the flue gas desulphurisation plants of units 5 … · 2015-12-02 · (FGD) absorbers based on the lime-gyp-sum method. The first FGD plant was put into service in

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