WET FLUE GAS
DESULFURIZATION ( FGD)
SYSTEMS
ADVANCED MULTI-POLLUTANT
CONTROL TECHNOLOGY
B&W WET FGD SYSTEMS –
FLEXIBILITY OF DESIGN AND ADVANCED FEATURES
TO MEET CUSTOMER NEEDS
When performance counts
SINCE 1971, BABCOCK & WILCOX’s (B&W) WET FLUE GAS DESULFURIZATION (FGD)
SYSTEMS, OR SCRUBBERS, HAVE OPERATED EFFICIENTLY, ECONOMICALLY AND
RELIABLY, HELPING OUR CUSTOMERS MEET PERMIT REQUIREMENTS WHETHER
AS A NEW SOURCE OR RETROFIT APPLICATION. CURRENT DESIGNS CAN ACHIEVE
MORE THAN 99% REMOVAL OF SULFUR DIOXIDE (SO ). IMPROVEMENTS IN
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B&W’s WET SCRUBBER DESIGN AND AUXILIARY EQUIPMENT HAVE RESULTED IN
SYSTEM AVAILABILITY GREATER THAN 99.5%. MULTI-POLLUTANT CONTROL
CAPABILITIES INCLUDE FILTERABLE PARTICULATE, ACID MIST AND MERCURY.
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Current B&W designs are achieving 99% SO2 removal with system availability greater than 99.5%.
Controlling oxidation a worldwide leader in supplying
limestone forced oxidation units,
and plugging in the tower, allows
the use of less expensive materials,
New wet FGD systems can be and we continue to support this and eliminates the wastewater
supplied with either forced technology. discharge stream. This process can
oxidation or inhibited oxidation. be utilized with various reagents
While limestone forced oxidation — limestone, lime, magnesium-
Since the mid-1980s, limestone technology has proven successful enhanced lime, or sodium.
forced oxidation has been the in many worldwide installations,
leading wet FGD technology. This
beneficial process converts calcium
in some applications, the gypsum
byproduct is no longer marketable,
Scope of supply
sulfite to calcium sulfate within and wastewater treatment and B&W is a full-scope supplier. In
the absorber reaction tank and discharge have become a concern. addition to flue gas absorbers,
improves scrubber operation while Therefore, some customers we supply reagent preparation
producing a marketable gypsum believe that a dry FGD system is systems, dewatering systems and
byproduct. B&W has more than the only option. However, there related system equipment. We also
34,000 MW of commercial units is an alternative: existing wet provide complete construction
successfully operating with forced FGD technology with inhibited services through our subsidiary,
oxidation, both in situ systems and oxidation. In this process, emulsified Babcock & Wilcox Construction Co.,
units operating with specialized sulfur, or sodium thiosulfate, is Inc. (BWCC).
systems that are separate from added to the reagent feed tank.
the absorber reaction tank, The addition of emulsified sulfur B&W employs an experienced
most notably on magnesium- reduces the oxidation rate to below staff of design engineers, graphic
enhanced lime systems. We are 15%, thus controlling scale deposits designers, project managers, and
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As a full-scope supplier, B&W can provide complete wet FGD systems including reagent preparation, dewatering and
other system equipment, as well as a wide range of multi-pollutant control technologies.
the industry’s largest network of included improved SO2 removal, smaller boilers feeding one absorber
field service engineers, including reduced absorber pump power and three larger units feeding two
wet FGD field specialists, to consumption and maintenance absorbers.
support project development, costs, reduced limestone
project execution, and long-term
operation and maintenance. We
consumption, the elimination of
costly additives, decreased landfill Choice of reagents
also conduct extensive research requirements, and the opportunity We have designed FGD systems
and development (R&D) activities to to provide a marketable byproduct. using a variety of reagents. While
continue product advancement. most of our experience is with
Fuel Experience limestone, designs have utilized
Experience Our operating experience
encompasses a complete range
lime, magnesium-enriched lime,
and waste soda ash. Limestone-
Original Equipment Supply of fuels including bituminous, based systems using organic acid
At the time of publication, B&W subbituminous, Powder River Basin enhancement have also been
has provided wet FGD systems for (PRB), lignite and brown coals, as provided.
a total scrubbed capacity of more well as various coal blends. We have
than 43,000 MW. Through licensees
in China and Germany, our wet FGD
also provided systems for heavy oil
and Orimulsion fuels.
Advanced design benefits
technology has been utilized for an We continue to optimize our FGD
additional capacity of more than Large, Single Absorbers systems by refining the technology
77,000 MW. to improve SO2 removal efficiency,
As the technology of wet FGD
improve long-term operating
systems has improved, typical units
Upgrades reliability, and reduce capital and
have a single absorber module.
B&W has also improved the maintenance costs. As an indication
B&W absorber modules have been
performance of more than 13,000 of our constant efforts to improve
installed on boilers up to 1,300 MW.
MW of non-B&W wet FGD systems our designs, we currently have
Absorber design and reliability
by replacing the original absorber more than 40 patents involving wet
allow many utilities to treat the
internals with our absorption tray FGD technology.
flue gas from multiple boilers with
technology, modern spray headers, one absorber. To reduce project
and through forced oxidation costs B&W and our licensees have
conversions. Benefits have provided systems with two to four
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B&W’s wet FGD systems operate efficiently,
economically and reliably on a variety of
worldwide fuels to help our customers meet
permitting and operating requirements.
The B&W Absorber
A proven design for high optimum SO2 removal. An efficient
spray header and nozzle system is
distribution, which results in zones
of either inadequate or excess slurry
SO2 removal used to evenly distribute the liquor, and reactant. With the tray, flue gas
B&W’s absorber design features while the tray distributes the gas is uniformly distributed for the most
provide the highest levels of SO2 flow. As determined by both physical efficient SO2 removal.
removal, reduced operating costs and computer modeling, the gas-
and significant reductions in side pressure drop induced by the The tray is rugged and can be used
maintenance costs compared to other slurry sprays is not sufficient alone to as a convenient inspection and
technologies. These benefits allow our adequately distribute the flue gas at maintenance platform when using
customers to stay competitive with the base of the spray zone. In open appropriate planking. Costly and
today’s increasingly more stringent spray towers, uniform gas distribution time-consuming scaffolding from the
environmental requirements. is not achieved as effectively. bottom of the reaction tank is not
required.
Absorber design The B&W tray design effectively
achieves uniform gas distribution, Our tray design has been proven
Our absorber module is a counter- which becomes even more critical through extensive laboratory testing
current flow design. Slurry is sprayed in larger diameter spray absorber and modeling and many years of
downward from a series of headers towers. Without a tray, some zones successful operation.
and nozzles and scrubs the flue gas of the absorber have poor gas
as it moves upward through the
absorption tray and spray zone. The
control system automatically adjusts
the feed of fresh reagent to achieve Clean
Conical
an outlet SO2 emission limit or the Outlet
Flue Gas
Out
required SO2 removal efficiency.
Absorber tray system Interspatial
Moisture
Separators/
Our absorber tray system serves the Spray Mist Eliminators
Levels
dual purpose of providing gas-liquid SO2 and
contact for SO2 absorption and more Flue Gas In
uniform distribution of flue gas across
the tower. The gas rises through the
absorber, contacting a froth of slurry
on the tray. This action results in
efficient contact of gas and reagent
throughout the absorber.
Gas
Distribution
Trays
Our absorbers use one or two
trays depending upon the fuel and Oxidation
Zone
specified requirements for SO2
Oxidation
removal and operating parameters. Air Supply
The tray provides uniform gas
distribution and effective gas-slurry
contact. Table 1 summarizes the
benefits of the B&W tray absorber Slurry
tower design. Agitators
The slurry and the flue gas must
be uniformly distributed across the Recirculation
Pumps
absorber tower’s cross-section for Forced oxidation system shown.
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a) Wet FGD Without B&W Tray Gas Velocity b) Wet FGD With B&W Tray
Magnitude
(ft/s)
30
28
Outlet 26 Outlet
24
22
20
18
16
14
10
8
6
4
2
0
Mist Eliminator 2 Mist Eliminator 2
Mist Eliminator 1 Mist Eliminator 1
Spray Header 2 Spray Header 2
Spray Header 1 Spray Header 1
Tray
Inlet Inlet
Slurry Level Slurry Level
High gas velocity in spray area is less effective. Uniform gas distribution through spray zone(s)
results in more effective and efficient SO2 removal.
B&W uses both advanced numerical modeling and physical modeling to design the most efficient wet flue gas
desulfurization systems.
TABLE 1
EXAMPLE ABSORBER COMPARISON
Unit Size: 617 MW SO2 Inlet: 1,100 ppmdv
Reagent: Limestone SO2 Removal: 97.6%
2 Trays 1 Tray Open Tower
L /G 56 82 108
P, in. wc 10.2 8.2 7.0
Pump Flow, gpm 34,500 50,000 66,000
B&W’s absorption tray provides uniform
Fan/Pump Power, kw 6,470 6,560 7,470
gas flow and maximizes SO2 removal. This
photo shows a tray after two years of
Power Base +90 +1,000 continuous service.
Pump/Header Cost Base +$400k +$700k
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Patented interspatial Patented inlet awning
headers B&W’s patented inlet awning design
prevents the buildup of deposits in
Achieving overlapping spray
the absorber inlet flue. The awning
coverage with an effective spray
deflects the falling slurry away
header design is critical for optimal
from the inlet, shifting the wet-dry
SO2 removal performance. B&W’s
interface out into the absorber
patented interspatial header
away from the inlet flue. This design
technology allows the location
provides high reliability and lower
of two spray headers at the same
maintenance costs.
elevation while maintaining full
overlapping coverage with one or
both spray headers in service. The
use of interspatial spray headers
results in a shorter absorber tower,
reduced pump power, lower
building height, less external
recirculation piping, and easier
nozzle inspection and maintenance.
Moisture separator
Efficient moisture separation
is essential to prevent slurry
carryover and deposition in the
flue downstream of the module. Deposit buildups in the absorber inlet
Our absorbers utilize two or three flue are reduced by B&W’s patented
inlet awning.
levels of moisture separators that
are rugged in design and have a
history of low replacement. We Tank agitators
have performed extensive R&D
Slurry in the recirculation tank
Two levels of moisture separators to optimize gas flow distribution,
is agitated to keep the solids in
effectively prevent slurry carryover and develop velocity profiles, and
suspension. Our standard design
deposition in the downstream flue. test the performance of moisture
allows for operation with one of
separators in our hydraulic model.
the agitators out of service for high
We also work closely with our
system reliability.
suppliers in the development
of advancements to moisture
separator technology. Materials of construction
We can supply absorber modules in
a variety of materials for dependable
operation and reliability: rubber and
flake glass lined, tile-lined concrete,
tile-lined carbon steel, stainless steel,
and other specialty alloys. Abrasion-
resistant fiberglass reinforced
piping (FRP) or alloy piping can be
used for internal spray headers.
Multiple side-entering agitators on
Abrasion-resistant materials are
B&W’s absorber tower provide uniform
used for the spray nozzles. External
slurry mixing.
piping is typically FRP or rubber-
lined carbon steel.
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B&W’s interspatial spray header
design provides complete spray
coverage for optimal performance
and easier maintenance.
Multi-pollutant capability a minimum of 90% removal of
oxidized mercury can be achieved.
As a multi-pollutant control device, Recognizing that oxidized mercury
B&W’s wet scrubber provides is water soluble and elemental
control of several pollutants in mercury is not, we developed the
addition to SO2. Absorption Plus (Hg)™ system, a
patented technology to inhibit
Filterable (solid) particulate is mercury re-emission and to
removed in the wet scrubber. The increase the total mercury captured
wet scrubber removes 40 to 90% and retained in a wet FGD system.
of the flyash entering the scrubber,
depending upon the ash inlet
loading and the type of upstream Extensive R&D activities
particulate collector. for improved performance
B&W is continuously working
Acid mist (H2SO4) is removed in to improve our wet scrubber
the wet scrubber. The removal product line. Our research center is
is dependent upon a number of equipped with a wet scrubber pilot
operating conditions such as gas plant. The flue gas is supplied by a Through extensive research and
temperature, gas humidity, inlet development, B&W scientists
small boiler unit capable of firing a
concentration, etc. H2SO4 removal in continually strive for product
variety of coals, liquid and gaseous improvements to help our customers
wet scrubbers ranges from 35 to 70%. fuels. We also use an advanced reduce emissions.
hydraulic model to study tray and
Mercury is also removed in the wet spray fluid hydraulics and mist
scrubber. Using B&W’s patented eliminator carryover.
and proprietary additives that are
injected directly into the absorber,
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We are the only FGD supplier with a full capability
construction company operating as a subsidiary on
the same campus. Complete project integration, from
concept to commercial operation, is necessary to control
costs and schedule and is achievable through the team
of B&W and BWCC.
Full-Scope Integration
Modularization to collaborate with our customers
and key suppliers on ideas and
injection systems for acid gas
control, various mercury mitigation
B&W designs its scrubber systems with solutions and ultimately share in technologies, low NOx combustion
modularization in mind. Components the cost savings that can result from systems, and selective catalytic and
are manufactured to minimize on- such an arrangement. Effective non-catalytic reduction systems for
site labor requirements, particularly communication and trust are vital to NOx control. In addition, B&W provides
in locations with limited laydown make any project a success. a complete package of aftermarket
area. This technique significantly services including engineered
reduces both the project schedule
and construction costs and represents Total-scope services equipment upgrades, startup and
commissioning, performance testing
an important advancement in B&W provides total-scope services, and monitoring, field engineering
manufacturing and construction such as project engineering and replacement parts, and emissions
technology. and management, component monitoring products and services.
fabrication, and installation of
Project management complete environmental emissions
control equipment. In addition to
Our FGD systems
are backed by
Many times, a project calls for new wet scrubbers, our environmental an experienced
ways of thinking. Our innovation equipment capabilities include staff of design
goes beyond traditional project dry FGD systems with spray dryer engineers, project
management and vendor/supplier absorbers or circulating dry scrubber managers and a
relationships. Innovative approaches, technology, fabric filter baghouses, network of field
such as strategic alliances, allow us electrostatic precipitators, sorbent service engineers.
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Selected B&W Wet FGD Projects
DETROIT EDISON, MONROE
UNITS 1 THROUGH 4
Nominal Boiler Capacity (combined) 3300 MW
Nominal Scrubber Capacity (ACFM, per unit) 2,723,000
Inlet SO2 Concentration (ppm, per unit) 1158
Percent SO2 Removal 97%
Commercial Operation June 2009 (Unit 4)
October 2009 (Unit 3)
November 2013 (Unit 1)
April 2014 (Unit 2)
Fuel Pulverized PRB/Bituminous Coal Blend
Reagent Limestone
Oxidation Method Forced Oxidation
WESTERN U.S. UTILITY
UNITS 1 AND 2
Nominal Boiler Capacity (combined) 397 MW
Nominal Scrubber Capacity (ACFM) 834,274 (Unit 1)
1,081,788 (Unit 2)
Inlet SO2 Concentration (ppm) 1411 (Unit 1)
1443 (Unit 2)
Percent SO2 Removal 97%
Commercial Operation 2011/2012
Fuel Pulverized Coal
Reagent Soda Liquor
GENON ENERGY, CHALK POINT, DICKERSON,
MORGANTOWN UNITS 1 AND 2
Nominal Boiler Capacity (combined) 2390 MW
Nominal Scrubber Capacity (ACFM) 2,513,000 (Chalk Point)
2,146,000 (Dickerson)
2,102,000 each (Morgantown Units 1 and 2)
Inlet SO2 Concentration (ppm) 1554 (Chalk Point)
1666 (Dickerson)
1711 each (Morgantown Units 1 and 2)
Percent SO2 Removal 98%
Commercial Operation 2009
Fuel Pulverized Bituminous Coal
Reagent Limestone
Oxidation Method Forced
Established in 1867, Babcock & Wilcox is a global leader
in advanced energy and environmental technologies
and services for the power and industrial markets, with
operations, subsidiaries and joint ventures worldwide.
For more information, or a complete listing of our sales
and service offices, send an e-mail to info@babcock.
com, or access our website at www.babcock.com.
www.babcock.com
HELPING OUR CUSTOMERS
PROVIDE CLEAN POWER
Working with our customers, B&W provides worldwide
leadership in environmental products and services
by applying the best available technology through
innovation, responsiveness and commitment.
Babcock & Wilcox
20 S. Van Buren Avenue
Barberton, Ohio 44203 USA
Phone: 330.753.4511
Fax: 330.860.1886
The information contained herein is provided for general information
purposes only and is not intended nor to be construed as a warranty, an
offer, or any representation of contractual or other legal responsibility.
Absorption Plus (Hg) is a trademark of The Babcock & Wilcox
Company.
© 2014 The Babcock & Wilcox Company. All rights reserved.
E101-3167B 1KG4G
