lc-6 flue gas monitoring for coal fired thermal power plant

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Technology TransferTechnology Transfer

Flue Gas Monitoring Flue Gas Monitoring for Coalfor Coal--fired Thermal Power Plantfired Thermal Power Plant

July 2010

J-POWER Tachibanawan Thermal Power Plant（1,050MWx2Units)

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Content of Presentation

•Introduction

•Air Quality and Emission Standards

•Flue Gas Treatment Facility

• Flue Gas Monitoring System

• Manual Measurement of Flue Gas

•Introduction

•Air Quality and Emission Standards

•Flue Gas Treatment Facility

• Flue Gas Monitoring System

• Manual Measurement of Flue Gas

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•Program-1: Introduction•Program-1: Introduction

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The leading part of the energy sources used all over the world consists of fossil fuel such as coal and heavy oil. When any kind of the fossil fuel is converted into energy, it always generates nitrogen oxide (NOx), dust and sulfur oxide (SOx), all of which cause air pollution.

Japan has experience of that various types of bronchus-related disease including asthma were caused by air pollution in areas dense with factories during 1960s. In those days, there were not enough air pollution control equipment in the country.Facing the problem, the Japanese Government established Air Pollution Control Law in the '70s. This movement rapidly developed air pollution control technology. Since then, more and more air pollution control systems have been introduced in plants in earnest.

The following shows the typical flue gas treatment system for coal-fired boilers currently used in Japan:

INTRODUCTIONINTRODUCTION

Gas-gas heater(GGH)

Boiler

Gas air heater

Electric precipitator

DeSOx(FGD) System

Desulfurizationdraft fan(BUF)

Stack

DeNOx(SCR) System

Forced draft fan

Induceddraft fan

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Electricity pricing:

Electricity rates in Japan are based on the average cost of supplying electricity. This method, The Total Cost of Services Method, is stipulated in Article 19 of the Electricity Utilities Industry Law. The article provides that general power utilities draw up a supply contract, including electricity rates, and obtain authorization of the Central Government “such as METI”.

The contract will be authorized if the METI thinks it reflects “proper costs, based on efficient business management, plus fair return. “Proper costs” are calculated by adding up expenses for personnel, fuel, maintenance, and depreciation, as well as costs for wastewater treatment, exhaust gas treatment, and other environmental measures. “Fair return” is calculated on the Rate Base Method by multiplying business assets invested (including facilities for generation, transmission, and distribution) by a certain rate of return. Adding up the above-mentioned costs and remuneration and deducting the target figure for management effort gives the total cost, which is used as the basis for calculating electricity rates.

The cost calculation method allows electric power companies to take necessary measures to protect the environment and pass on the costs to consumers, thus recovering the environmental cost of power generation. Although this system tends to drive up the electricity price in Japan (it is higher than in other countries), it was Japan’s choice to spend more on environmental protection and energy security.


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Government Subsidies for Environmental Measures

The biggest problem implementing environmental measures is economic.Environmental equipment requires large amounts of initial investment and funding, and operating, and operating the equipment requires power to run the devices and expendable supplies like treatment chemicals. Power generation itself requires large amounts of capital investment, and additional investment significantly burdens companies. Electric power companies must be socially responsible and take environmental measures while meeting their responsibility to provide a steady supply of energy at an affordable price.

The government has introduced assistance programs to relive the financial burden and to give business the incentive to protect the environment. Following are the main efforts by the government to support environmental measures in the electric power industry: (1) a low-interest-rate loan program through the Japan Development Bank for pollution control facilities, energy efficiency enhancement facilities, and recycling facilities; (2) preferential tax treatment through accelerated depreciation of equipment for environmental measures, reduction or exemption of fixed property taxes related to environmental facilities, and tax deductions on energy-saving technology R&D; and (3) subsidy for R&D of environment-friendly technology.


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•Program-2:

Air Quality and Emission Standards

•Program-2:

Air Quality and Emission Standards

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Environmental Survey to Environmental MonitoringEnvironmental Survey to Environmental Monitoring

Prediction and Evaluation of

Impact on Environment

Prediction and Prediction and Evaluation of Evaluation of

Impact on Impact on EnvironmentEnvironment

Countermeasures of Environmental

Conservation

Countermeasures Countermeasures of Environmental of Environmental

ConservationConservation

Environmental Monitoring

Environmental Environmental MonitoringMonitoringConstructionConstruction

EmissionStandard

Environmental Quality

Standard

EIA surveyEIA survey

Regulation

MonitoringExhaust gas,Waste water,

Sound, etc

MonitoringMonitoringExhaust gas,Exhaust gas,Waste water,Waste water,

Sound, etcSound, etc

++

Environmental Survey

Environmental Environmental SurveySurvey

Surveys on the conditions undertaken at the planned power plant

Plant operation

EmissionStandard

New valueNew value

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Why is the Monitoring of SOx, NOx etc necessary?

It affects the Human healthand is also a substance causing Acid Rain

Air polluted by NOx causes disease of Human respiratory organs(Nose, throat and breast hurt, breath difficulty, cough, sputum)

Photochemical Oxidant arises by the photochemical reaction, and it cause not only bad influence to Human membrane and breath, but also affects Plant Growth (Agricultural products).

SPM sticks to Human respiratory tract and lungs, and causes a Respiratory-organs disease

NOx:NOx:

SOx:SOx:

SPM:SPM:

++HCHC

Regulation

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WHO World Bank

Vietnam TCVN5937-1995

Japan Pollutant

μg/m3 μg/m3 μg/m3 μg/m3 ppm

SO2 Annual 24 hr 8 hr 1 hr

40-60 110-150

- -

80 150

- -

- 300

- 500

- (110)

- (286)

- 0.04

- 0.1

NO2 Annual 24 hr 8 hr 1 hr

- 150

- 400

100 150

- -

- 100

- 400

- (82-123)

- -

- 0.04-0.06

- -

SPM Annual 24 hr 8 hr 1 hr

- 70 - -

50 150

- -

- 200

- 300

- 100

- 200

- - - -

*Japanese 24hr Ave: Daily Average of hourly values*Parenthesis indicates converted value

Comparison of the Environmental Air Quality StandardsComparison of the Environmental Air Quality Standards

Regulation

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Comparison of the Emission StandardsComparison of the Emission Standardsfor Coal fired Power Plantfor Coal fired Power Plant

Regulation

50

750

(365 ppm,260 mg/MJ)

2,000

(700 ppm)

100 - 500 t/d

World Bank

411 (700*103 Nm3/h)*

514 (400~700*103

Nm3/h)*

850850NOx

mg/Nm3

*: Exhaust gas volume

Remarks

50~100 (>200*103Nm3/h)*

100~200(40~200*103Nm3/h)*

98.9170Dust

mg/Nm3

K-Value rule

Example of 500MW

K: 3.0→ 600K:17.5→ 3,457

425425SO2

mg/Nm3

JapanGuaranteed

Parameters

at Nghi Son 1

VietnamTCVN7440-2005

Pollutant

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Environmental Management in Thermal Power Plants

• Control of facility’s efficiency

• Control of environmental pollutants

• Dealing with local residents and government concerning environmental issues

• O&M of environmental management system

E M S

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Efficiency Control of Equipment

• Efficiency of the boiler and turbine

• Dust collection efficiency of the electric precipitator

• Efficiency of the denitrification facility

• Efficiency of the desulfurization facility

• Efficiency of the waste water treatment facility

E M S

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Control of Pollutants

• Emission gases

– (SOx, NOx, dust, O2)

• Water quality

– (PH, COD, N, P, etc.)

• Noise

• Vibration

E M S

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•Program-3:

Flue Gas Treatment Facility

•Program-3:


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Environmental conservation countermeasuresfor thermal power plant


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Flue gas treatment facility


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Boiler

ESP SCR AH GGH GGHFGD

Boiler outletSO2: 3150 mg/m3

NOx: 620 mg/m3

Dust: 22600 mg/m3

Agreement valueSO2: 283 mg/m3

NOx: 123 mg/m3

Dust: 40 mg/m3

Flue Gas Treatment System at Matsuura PS Flue Gas Treatment System at Matsuura PS (1000MW(1000MW××2u)2u)

ESP SCR

Stack

FGD

FlueGas


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DustDust Removal TechnologyRemoval Technology-- ESPESP


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DustDust Removal TechnologyRemoval Technology-- ESPESP


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130℃

Dust 150 mg/m3N

Boiler

SOx SOx ControlControl -- FGD SystemFGD System

Gypsum Process

IDF

GGH

FGD

BUF

ESP

Stack

Limestone - Gypsum Process

DeSOx η> 90%


SCR AH

SOx 1000 ppm

NOx 300 ppm

Dust 20 g/m3N

SOx <50 ppm

NOx <36 ppm

Dust 20-30mg/m3N

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BoilerSCR AH

ESP Dry DeSOx

Stack

10 mg/m3N20 ppm20 ppm

ParticulateNOxSOx

Stack Gas

SOx SOx ControlControl –– Dry Dry DeSOxDeSOx SystemSystem

Activated Carbon Process η>90%

SOx 1000 ppm

NOx 300 ppm

Dust 20g/m3N

Activated Carbon

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SOx SOx ControlControl –– Spray Dryer SystemSpray Dryer System

LimeSlaker

Boiler ESP

Spray Dry Absorber

ESP

Calcium sulphate

Fly ash, etc.

FGD Fan

Stack

DeSOx η> 80~90%


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350℃

DeNOxDeNOx TechnologyTechnology-- SCRSCR

Cat

alys

t

NOｘ NH3

NH3

NH3

NH3NOｘ

NOｘ

NOｘ

Ｎ2H2O

H2O

H2O

H2O

Ｎ2

Ｎ2

Reaction on the Catalyst Surface

4NO＋4NH3＋O2 → 4N2 + 6H2O

6NO2 + 8NH3 → 7N2 + 12H2O

NH3 (Ammonia)

Inlet NOx180 ppm

Outlet NOx<36 ppm

Removal efficiency η>80%


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Features

Principal reaction in Absorber

SO2 + CaCO3 + 1/2O2

(Limestone)

→ CaSO4・2H2O + CO2

(Gypsum)

Simple Configuration

Aptitude for Large Capacity

Low Pressure Loss

Clogging Free

Easy Maintenance

Removal efficiency η>(80% - 90%)

DeSOxDeSOx TechnologyTechnology-- SPRAY TOWER ABSORBERSPRAY TOWER ABSORBER

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FGD FGD System for Coal Fired BoilerSystem for Coal Fired Boiler (Lime stone process)(Lime stone process)

Isogo #1 & 2265 MW, Completion: 1976

～ 300 MW FGD

Ishikawa #1 & 2156 MW, Completion: 1986

Matsushima #1500 MW, Completion: 1981

500 MW FGD

Shin-Onoda #1 & 2500 MW, Completion: 1986

Tsuruga #1500 MW, Completion: 1991

Reihoku #1700 MW, Completion: 1995

700 ～ 1000 MW FGD

Thai Union Paper Public Co,. LtdIn-line Type, Completion: 1997

Matsuura #21000 MW, Completion: 1997

Tsuruga #2700 MW, Completion: 2000


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•Program-4:

Flue Gas Monitoring System at Coal Fired Power Plant

•Program-4:

Flue Gas Monitoring System at Coal Fired Power Plant

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Environmental conservation countermeasuresfor thermal power plant

Flue Gas Monitoring System

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StackStack

FGDGGH

Sampling Point

(Stack inlet)

Stack Gas Monitoring Devices (SOx & NOx)Stack Gas Monitoring Devices (SOx & NOx)at Matsuura Thermal Power Plant of JPOWERat Matsuura Thermal Power Plant of JPOWER

MD

Non-Dispersive Infrared AbsorptionType for SOx & NOx

(Maker: HORIBA)


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StackStack

FGDGGH

Central Control Roomat Power Station

MonitoringDevice

(Image)

Telemeter System of Stack Gas Monitoring Telemeter System of Stack Gas Monitoring at at JPOWERJPOWER’’ss Thermal Power Plant in JapanThermal Power Plant in Japan

Local Authority

Office

Transmitted ItemsSO2 , NOxGas Volume

Transmitted ItemsSO2 , NOx, etc.

MD


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Environmental Observation Station



Regional Monitoring Center

Regional Monitoring Center

Central Monitoring Center

Data input

Central Monitoring Center

Data processor

Telemetermother stationequipment

Central processing system

Factories, power stations, etc.

Radio relay station Mobile measurement vehicle

Pollution monitoring vehicle

Evaluation and study of emergency

General household Municipal government

School

Notification of emergencyInformation

Administrative order

Request of cooperation

Via relay station

Display board Control desk

Console

Message Printer

Table Printer

Console

Disk

Tape

Printer

System Diagram of Air Pollution Monitoring Telemeter System


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•Program-5:

Manual Measurement of Flue Gas at Ninh Binh TPP

•Program-5:

Manual Measurement of Flue Gas at Ninh Binh TPP

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Necessity & Convenience of Manual Measurement

Thermal power plant has to carry out a manual measurement at least twice a year, if the stationary automatic device is notinstalled.

Considering the management of flue gas treatment facilitybased on the EMS, Manual measuring procedure is veryuseful due to measure flue gas at inlet & outlet of ESP, FGDand so on.

It is necessary to follow up periodical monitoring, when the stationary automatic device is malfunctioning and it takes long time to repair.

Manual measurement data of SO2 and NOx are able to use forchecking stationary monitoring device.

Convenience:Convenience:

Necessity:Necessity:

Manual Measurement of Flue Gas

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Boiler ESPStack

Measuring location:

ESP outlet

Main items:

SO2, NOx, Dust

Measuring location and items at Ninh Binh TPPMeasuring location and items at Ninh Binh TPP


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Section plan: seen from upper stream of ESP

Duct area: approx. 6.75m2

Numbers of samples: 12~16 ponitsDuct of ESP outlet

Sampling point at ESP outletSampling point at ESP outlet

Flue gasFlue gas

Sampling point


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Outline of gas samplingOutline of gas sampling

Measurement of Gas velocity

Gas velocity has to calculate due to decide gas suction speed

Following items are to measure in whole measuring points in order to calculate gas flow velocity.

Dynamic pressure (Pa)Static pressure (Ps)Gas Temp. (Tg)

γh892

CVg.×=

769

PsPa

Tg273

27331

+×+

×= .γ

12~16 points

Decision of representative measuring points

Measuring point (1~ several points) most close to mean gas velocity has to choose as representative ones.

Decision of sampling points

1~3 points

Samples/unit/

・Dust: 2

・SO2: 2

・NOx: 2・Moisture: 2

Measurement of pollutants

Gas is to suck with equivalent speed to the gas velocity

Sampling


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Manual measurement procedureManual measurement procedure

Infrared absorption method(portable analyzer) in the field

Manual analysis*

Infrared absorption method(portable analyzer) in the field

Manual analysis*

Portable analyzer

HORIBA PG-250

(SO2, NOx, O2)

Sampling with filter paper (dust collector)

Dust quantity ⇒ Analysis in the laboratory

Sampling with filter paper (dust collector)

Dust quantity ⇒ Analysis in the laboratory

Chemiluminescence method(portable analyzer) in the field Manual analysis*

Chemiluminescence method(portable analyzer) in the field Manual analysis*

SO2

NOx

Dust

*Manual analysis: sample gas is to analyze in the laboratory

Adaptation of the portable analyzer is to evaluate comparing witAdaptation of the portable analyzer is to evaluate comparing with data of h data of manual analysismanual analysis


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Checking operation of pump, etc:- Every measurement -

Periodical inspection

Once a yearOverhaul by manufacturer

(Main materials)- Mist catcher (every 3 months)- Scrubber (ditto; for NOx meter)- Pump (every year)- NOx converter (every year)

Exchange of materials

Every measurement (Zero, Span drift)Calibration

FrequencyMaintenance Items

Example of Maintenance for Portable AnalyzerExample of Maintenance for Portable Analyzer

Material exchange: to be carried out in each accumulated operation period


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Example of manual dust monitoring equipment


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Sampling Probe Manometer

Manual gas measurement at stack inletManual gas measurement at stack inlet

Matsuura Thermal Power Station(Jan. 2003)


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Moisture absorber Dust sampling device

SO2 absorber & mist catcher NOx monitor (HORIBA)

Manual gas measurement (devices)Manual gas measurement (devices)


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(Example) Report of measuring result

*1: Calculation by Measured gas parameters

Plant output (kW)

Firing coal

Coal consumption (t/hr)

Contents of sulfur, nitrogen and ash in coal (%)

Unburned C in ash (%)

Plant operation conditions

Remarks:

Soot blowing to AH was carried out during 13:00~14:00

Flue gas volume *1

(wet & dry bases m3N/h)

Moisture in gas (%)

Gas temp. (degree C)

O2 conc. (%)

SO2 (mg/m3)

NOx (mg/m3)

Dust (mg/m3)

• Location

(Unit number, ESP outlet etc.)

• Date

• Time

• Weather

• Measuring method

Measurement resultsMeasuring condition


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Investigation on a relation between an environmental Investigation on a relation between an environmental monitoring result and the exhaust gas conditionmonitoring result and the exhaust gas condition

• Plant Operation situation

• Exhaust Gas Condition

Weather situation• Wind direction• Wind velocity

• Pollutants with high value

Weather Data• Wind direction• Wind velocity

Air Monitoring Place Power Station

Example ofInvestigation Dispersion Calculation of Pollutants from the StackDispersion Calculation of Pollutants from the Stack


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Thinking of Evaluation on the Monitoring Data Thinking of Evaluation on the Monitoring Data by Dispersion Calculationby Dispersion Calculation

Present Level

It is estimated, whether or not the contribution value of Flue Gas influences a present environmental value.

It is also necessary, to evaluate the proportion of ground concentration level to the present condition value.

This contribution value might be more than the present environmental value, even if this total value is standard range inside.

Ground Concentration

Level

Air qualityStandard


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Thinking of Evaluation on the Monitoring Data Thinking of Evaluation on the Monitoring Data by Dispersion Calculationby Dispersion Calculation

Air qualityStandard

Present Level In case that an environment level has already

been exceeding the standard after commencement operation of the plant, a proportion of ground concentration level to the present environmental value is estimated.

Countermeasure of the flue gas treatment might have to be required, even if this contribution value is small comparing with the present environmental value.

Ground Concentration

Level
