Air quality control system: De-Sox Projects & De-Nox Projects
- 1. AIR QUALITY CONTROL SYSTEM (AQCS) PROJECT STORIES De-Sox Projects De-Nox Projects 1. Orot Rabin Unit 5 & 6 FGD Add-on (Israel) 2. Yongheung Unit 1 & 2 FGD Add-on (Korea) 3. Shinboryeong Unit 1 & 2 FGD Add-on (Korea) 4. ShinSeochon FGD Add-on (Korea) 1. Castle Peak TPP Emission Control (Hong Kong) 1.1 Summary 1.2 Detailed Scope of Work 1.3 Field Work 2. Ratcliffe SCR Add-on (UK) 2.1 Summary 2.2 Detailed Scope of Work 2.3 Field Work Copyright by Doosan Heavy Industries & Construction Co., Ltd. All Rights Reserved.
- 2. DOOSAN POWER SERVICES PROJECT STORIES DE-SOX PROJECTS 1.0 Orot Rabin Unit 5 & 6 FGD Add-on (Israel) PROJECT OVERVIEW PLANT LOCATION Hadera, Israel Plant Information ∙ Plant Type ∙ Capacity ∙ Fuel Subcritical 575MW x 2 Coal (1.12% Sulfur) ∙ FGD on a turn-key basis with equipment as follows: - Absorbers island - Reagent preparation system, WWTP - Limestone gypsum handling system - Gypsum dewatering system - Electrical, instrumentation and control - Flue gas ductwork, piping ∙ FGD specifications Scrubbing reagent Limestone Capacity 2,887,896Am3 /h Inlet SO2 785ppm SO2 removal efficiency 95.55% SO2: 100mg/Nm3 No. of absorber 1 per boiler No. of spray level 3+1 Scope of Supply PJT title Orot Rabin Unit 5 6 FGD Add-on Client IEC (Israel Electric Corporation) Contract year 2010 Installation
- 3. DOOSAN POWER SERVICES PROJECT STORIES DE-SOX PROJECTS 2.0 Yongheung Unit 1 2 FGD Add-on (Korea) PROJECT OVERVIEW PLANT LOCATION Yongheung, Korea Plant Information ∙ Plant Type ∙ Capacity ∙ Fuel Subcritical 800MW x 2 Coal (1.0% Sulfur) ∙ FGD on a turn-key basis with equipment as follows: - Absorber, GGH - Limestone gypsum handling, WWTP - Reagent preparation gypsum dewatering - Electrical, Instrumentation and control - Buildings ∙ FGD specifications Scrubbing reagent Limestone Capacity 3,667,200Am3 /h Inlet SO2 429ppm SO2 removal efficiency 94.5% Dust: 20mg/Sm3, SOx: 25ppm No. of absorber 1 per boiler No. of spray level 3+1 Scope of Supply PJT title Yongheung Unit 1 2 FGD Add-on Client KOSEP Contract year 2002 Installation
- 4. DOOSAN POWER SERVICES PROJECT STORIES DE-SOX PROJECTS 3.0 Shinboryeong Unit 1 2 FGD Add-on (Korea) PROJECT OVERVIEW PLANT LOCATION Shinboryeong, Korea Installation Plant Information ∙ Plant Type ∙ Capacity ∙ Fuel Ultra supercritical 1,000MW x 2 Coal (1.3% Sulfur) ∙ FGD on a turn-key basis with equipment as follows: - Absorber, GGH - Limestone gypsum handling, WWTP - Reagent preparation gypsum dewatering - Electrical, instrumentation and control - Buildings ∙ FGD specifications Scrubbing Reagent Limestone Capacity 5,329,786Am3 /h Inlet SOx 1,114ppm SOx Removal Efficiency 95.5% Dust: 15mg/Sm3, SOx: 50ppm No. of Absorber 1 per boiler No. of Spray level 4+1 Scope of Supply PJT title Shinboryeong Unit 1, 2 FGD Add-on Client KOMIPO Contract year 2013
- 5. DOOSAN POWER SERVICES PROJECT STORIES DE-SOX PROJECTS 4.0 ShinSeochon FGD Add-on (Korea) PROJECT OVERVIEW PLANT LOCATION ShinSeochon, Korea Installation Plant Information ∙ Plant Type ∙ Capacity ∙ Fuel Ultra supercritical 1,000MW x 1 Coal (1.01% Sulfur) ∙ FGD on a turn-key basis with equipment as follows: - Absorber, non-leakage GGH - Limestone gypsum handling, WWTP - Reagent preparation gypsum dewatering - Electrical, instrumentation and control - Buildings ∙ FGD specification Scrubbing Reagent Limestone Capacity 5,489,880Am3 /h Inlet SOx 1,191ppm SOx Removal Efficiency 98.7% Dust: 3mg/Sm3, SOx: 15ppm No. of Absorber 1 per boiler No. of Spray level 4+1 Scope of Supply PJT title ShinSeochon FGD Add-on Client KOMIPO Contract year 2018
- 6. DOOSAN POWER SERVICES PROJECT STORIES DE-NOX PROJECTS | CASTLE PEAK TPP EMISSION CONTROL (HONG KONG) 5.1 Castle PeakTPP Emission Control (Hong Kong) PROJECT OVERVIEW PLANT LOCATION PJT title CP Emission Control Project Client China Light Power (CLP) Contract year 2007 PJT period 2007-2010 Tuen Mun NT, Hong Kong Plant Information ∙ Contractor ∙ Boiler OEM ∙ Plant Type ∙ Capacity ∙ Boiler ∙ COD Doosan Babcock BPL Coal-fired 660MWe x 4 (B Station) Subcritical, wall-fired PC boiler 1986 ∙ Emission reduction (NOx) ∙ Life extension Customer Needs ∙ Boosted over fired air (BOFA) for all four units on an EPC basis (330m of duct, 600t additional steel) ∙ Optimized selective catalytic reduction (OSCR) for all four units on an EPC basis - SCR civils - SCR mechanical - SCR ECI - Ammonia injection grid - Urea storage system - Feed water piping modifications - Air heater cold end element upgrade and new sealing system ∙ Reducing NOX emissions by 75% through the combination of BOFA and OSCR ∙ Extending lifetime of existing plants Scope of Supply Customer Benefits
- 7. DOOSAN POWER SERVICES PROJECT STORIES DE-NOX PROJECTS | CASTLE PEAK TPP EMISSION CONTROL (HONG KONG) 5.2 DetailedScope of Work Project Objectives Detailed Work Scope •NOx emissions reduction of 75% •High availability and flexibility of operations •Proven technology and robust design •No losses of boiler efficiency •EPC for boosted over fire air (BOFA) system - Design, fabrication, installation and construction - BOFA fans including civils - BOFA ducting - BOFA ports and pressure part modifications - Upgrade to DCS •EPC for selective catalytic reduction (SCR) - Design, fabrication and installation of an in-duct - Civil for support structure - SCR mechanical work - ECI for SCR - Ammonia injection grid - Urea storage system - Feedwater piping modifications •Air heater cold end element upgrade and new sealing system •Economizer outlet flue gas ducting retrofit BOX DUCTING DESIGN ECONOMIZER GAS OUTLET DUCT DESIGN Inlet AIG Expansion vanes Straightening vanes AH flange Catalyst GSG Mixer Turning vanes Lower tubes
- 8. DOOSAN POWER SERVICES PROJECT STORIES DE-NOX PROJECTS | CASTLE PEAK TPP EMISSION CONTROL (HONG KONG) 5.3 Field Work ∙Removal of cladding and lagging ∙ Dismantling of the horizontal section of the economizer outlet by removing panels ∙ The dismantling of the economizer outlet downward leg began with panel removal at the top flange of the heat exchanger, then working on the upward leg ∙ Corner sections of the ducting were kept in place until all the panel had been removed ∙ Cross member and stiffener removal throughout ∙Installation of a new SCR support beam ∙Removal of the structural I beam ∙Relocation (750mm) of the structural I beam ∙ Fabricated and installed associated bracings 1 Dismantling of the Economizer Outlet 2 Modification of the Structural Beam Relocation of economizer outlet beam (750mm) New SCR supporting beam Position of removed structural beam Bracing removal Panel removal
- 9. DOOSAN POWER SERVICES PROJECT STORIES DE-NOX PROJECTS | CASTLE PEAK TPP EMISSION CONTROL (HONG KONG) 5.3 Field Work ∙ 12 expansion vanes were erected from both ‘A’ and ‘B’ sides ∙ Held in position by using expansion vane support tubes ∙ 3 sections were erected separately, then welded into position ∙Installed before the inlet roof panels ∙ Lifted into place using runway beams, with a crane on standby ∙ Panels were erected from both ‘A’ and ‘B’ sides ∙ Commenced after intermediate beams were erected ∙ The process began at the lower levels, then progressed upwards ∙ Alignment and seal welding were required 3 Expansion Vanes 4 Static Mixer 5 Erection of the Reactor Panel 1st section of the static mixer Temporary guide beams Panel 1
- 10. DOOSAN POWER SERVICES PROJECT STORIES DE-NOX PROJECTS | CASTLE PEAK TPP EMISSION CONTROL (HONG KONG) 5.3 Field Work ∙ 1 section of economizer outlet rear was removed to enable the turning vanes to be lifted in ∙5 sonic horns for each reactor ∙Relatively inexpensive compared to soot blowers - Lower OM costs - The capital costs for sonic horns are 25% of those for soot blowers ∙ Horns which can be operated on standard plant compressed air ∙Small bore piping is rated for standard 70 to 90 psi ∙Frequent cycle keeps catalyst clean 6 Turning Vanes Ammonia Injection Grid (AIG) 7 Sonic Horns
- 11. DOOSAN POWER SERVICES PROJECT STORIES DE-NOX PROJECTS | CASTLE PEAK TPP EMISSION CONTROL (HONG KONG) 5.3 Field Work ∙ Capacity: 120m3 ∙ In order to ensure stability while the facility was being erected, the urea solutionizer tank, made of stainless steel, was half-filled with water to lower the center of gravity ∙ Supported by 8 load cells which determine the concentration of urea ∙ Capacity: 114m3 each ∙Positioned with crane ∙ In order to ensure stability before the steel support was being erected, the urea solution storage tanks were half- filled with water to lower the center of gravity ∙ 2 2'' pipes from the tank farm ∙ Stainless steel ∙ Carries urea to and from the decomposition chamber 8 AIG Storage: Urea Solutionizer Tank 9 AIGStorage:UreaSolutionStorageTanks 10 Ammonia Injection Grid (AIG)
- 12. DOOSAN POWER SERVICES PROJECT STORIES DE-NOX PROJECTS | RATCLIFFE SCR ADD-ON (UK) 6.1 Ratcliffe SCR Add-on (UK) PROJECT OVERVIEW PLANT LOCATION PJT title Ratcliffe SCR Add-on Client E.ON / UK Plc Contract year 2008 PJT period 5 years Nottinghamshire, UK Plant Information ∙ Plant Type ∙ Capacity ∙ Boiler ∙ Turbine ∙ COD Coal-fired 500MW x 4 Units Subcritical, conventional drum type TC3F – 3 Casings 1967 ∙ Emission reduction (NOx) ∙ High availability and flexibility Customer Needs ∙ On-site service team ∙ Supplying new SCR to all four 500MW subcritical units ∙ Partial replacement of boiler pressure parts ∙ Supplying an air pollution control system ∙ Technical support by highly skilled service engineers – approximately 4,000 people on site – working in confined operational areas ∙ Annual installation completed during unit shutdown while other 3 units being fully operational, without loss of boiler efficiency ∙ Building a strong, open contractual relationship which minimizes risk on challenging retrofit project ∙ Achieving NOx emissions limit of 100mg/NM3 in steady state condition ∙ Extending the plant life for continuing operations at the power station until the late 2020s Scope of Supply Customer Benefits
- 13. DOOSAN POWER SERVICES PROJECT STORIES DE-NOX PROJECTS | RATCLIFFE SCR ADD-ON (UK) 6.2 DetailedScope of Work Project Objectives Detailed Work Scope •Achieving NOx emissions limit of 100mg/NM3 in steady state condition. •Achieving high availability and flexibility of operations at SCR units over 15 years •No losses of boiler efficiency • All design, fabrication and construction work for 4 SCR units (8 reactor vessels) at Ratcliffe Power Station including: - Ammonia plant - Fans, motors, damper and ductwork - Ducting reactors (6,500 tons) - SCR economizer pressure parts (1,600 tons) - Piping valves (22,000m) - Structural steel (7,500 tons) - Dampers, expansion joints replacement - ID fan replacement, air heater modifications, ash handling system modifications, insulation, sonic horns - Specialist heavy lift crane - Civil work (2,500m3 concrete) - ECI work (Cabling 450km) FLUES, REACTOR AND BYPASS DESIGN
- 14. DOOSAN POWER SERVICES PROJECT STORIES DE-NOX PROJECTS | RATCLIFFE SCR ADD-ON (UK) 6.3 Field Work ∙ Design based on tied connection to the existing boiler house structure 1 SCR Supporting Structure 2 Installation Work