BHEL experience for emission norms below 30 mg/Nm3cdn.cseindia.org/userfiles/technology-options-overview-by-BHEL.pdf · Fuel Range: Indigenous / Imported coal Lignite Pith Bagasse

Welcome delegates

ROUNDTABLE ON POLLUTION

CONTROL TECHNOLOGY OPTIONS:

COAL POWER STATIONS

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ESP Profile - BHEL Experience…

Application:

Utilities up to 800 MW

Cement, Steel & Fertilizer industries

Chemical Recovery boilers

Bio Mass Application

Glass industries

Fuel Range:

Indigenous / Imported coal

Lignite

Pith

Bagasse

Rice husk / Rice Straw

Bark & All low grade fuels

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Capability:

Gas Flow up to 5.27 million

m3/hr (1465 cu.m/sec)

Emission level as low as

~17 mg/Nm 3

Collection Efficiency as high

as 99.97% and above

Complete Turnkey Systems:

Duct work & Dampers

Support steel structures

Thermal insulation

Integrated Control Systems

BHEL’s ESP Reference List

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APPLICATION NO. OF

PROJECTS

NO. OF ESPs

UTILITY BOILERS - PF Fired - 15 to 660

MW

447 1134

INDUSTRIAL BOILERS – CPP, VU40,

Stoker, etc

104 134

AFBC BOILERS – 25 to 165 TPH 57 57

CFBC BOILERS – 30 to 250 MW 18 33

CHEMICAL RECOVERY BOILERS – 75 to

900 TPD

46 70

OIL FIRED BOILERS -125 MW 3 3

BIOMASS – Upto 20 MW 50 50

CEMENT 16 16

STEEL 11 13

GLASS FURNACE 2 2

LIME KILN – 170 TPD - Paper plant 1 1

REFRACTORY - Magnesite 1 1

TOTAL 746 1514

FACTORS AFFECTING ESP PERFORMANCE

Indian ESP performance Vs Design

Parameters Variation Performance

Gas flow Increases Decreases

Gas temperature Increases Decreases

Inlet dust conc. Increases Decreases

Moisture in gas Increases Increases

Sulphur in coal Increases Increases

Ash Resistivity Increases Decreases

Un-burnt in ash Increases Increases

Particle size Increases Increases

BHEL supplied Electrostatic precipitators are

meeting the required performance levels as per design.

Operating parameters at ESP inlet like

Gas volume,

Gas temperature,

Inlet dust burden,

Coal quality,

Ambient conditions .

not vary much and to be maintained nearer to the design values

otherwise it will affect performance ie, emission will increase.

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Indian ESP performance Vs Design

ESP Upgradation Options –Merits and demerits

EMISSION WILL BE REDUCED BY

AUGMENTATION OF ESP COLLECTING AREA IN FOLLOWING WAYS: INSTALLING ADDITIONAL ESP PASSES IN PARALLEL

INSTALLING ADDITIONAL ESP IN SERIES.

REBUILDING THE EXISTING ESP BY INCREASING CASING HEIGHT

REBUILDING THE EXISTING ESP BY EXTENDING CASING LENGTH AT INLET

/OUTLET SIDE.

TOTAL REPLACEMENT OF EXISTING ESP WITH BIGGER NEW ESP.

RETAINING EXISTING ESP AND ADDING FIELDS IN SERIES AT INLET /OUTLET

SIDE

ENERGISATION WITH MICRO-PROCESSOR BASED

CONTROLLERS:

• INTRODUCTION OF INTERMITTENT CHARGING ESP MICRO

CONTROLLERS –Areca-ii

Providing solutions for a better tomorrow

MERITS AND DEMERITS OF ESP

UPGRADATION

REBUILDING THE EXISTING ESP

KEEPING THE LENGTH AND WIDTH OF THE EXISTING ESP, THE

MORE COLLECTING AREA CAN BE ACCOMMODATED BY

INCREASING THE CASING HEIGHT.

NO ADDITIONAL DUCT WORK AND HENCE NO ADDITIONAL

PRESSURE DROP

LONGER SHUT DOWN OF THE PLANT RESULTS MAJOR

REVENUE LOSS – A MAJOR CONSTRAINT.

ADDITIONAL CARE TO BE TAKEN TO CHECK THE EXISTING

FOUNDATION SHALL WITHSTAND ADDITIONAL LOAD

MERITS AND DEMERITS OF ESP

UPGRADATION

INSTALLATION OF ADDITIONAL ESP IN SERIES OR PARALLEL

NEEDS LESS DOWN TIME OF THE PLANT AS THE INSTALLATION

OF THE ADDITIONAL ESP IS A PARALLEL ACTIVITY

SHUT DOWN IS REQUIRED ONLY FOR HOOKING UP ACTIVITY

ADDITIONAL DUCT WORK AND HENCE THE ID FAN CAPACITY

TO BE CHECKED FOR HANDLING ADDITIONAL PRESSURE DROP

DUE TO ADDITIONAL DUCTING AND ESP CARE SHOULD BE

TAKEN TO ENSURE UNIFORM GAS DISTRIBUTION

Revised MOEF Notification dt 7th December 2015 Pollutants TPPs ( units) installed

before 31st December, 2003*

TPPs ( units) installed

after 1st January,2003,

upto 31st Dec , 2016*

TPPs ( units) to be installed

from 1st Jan, 2017**

Norms till 7th December 2015

Particulate Matter (PM)

100 mg/Nm3 50 mg/Nm3 30 mg/Nm3 100 mg/Nm3

Sulphur Dioxide (SO2)

600 mg/Nm3 (Units Smaller than 500MW

capacity units) 200 mg/Nm3 (for units

having capacity of 500MW and above)

600 mg/Nm3 (Units Smaller than 500MW

capacity units) 200 mg/Nm3 (for units

having capacity of 500MW and above)

100 mg/Nm3 Not Specified

Oxides of Nitrogen NOx)

600 mg/Nm3 300 mg/Nm3 100 mg/Nm3 Not Specified

Mercury ( Hg) 0.03 mg/Nm3(for units having capacity of 500MW and above)

0.03 mg/Nm3 0.03 mg/Nm3 Not Specified

*TPPs (units) shall meet the limits within two years from date of publication of this notification. **Includes all the TPPs (units) which have been accorded environmental clearance and are under construction”.

TYPICAL 210 MW- REBUILDING ESP AND ADDING NEW ESP IN PARALLEL

New taller parallel ESP

Providing solutions for a better tomorrow

UPGRADATION OF ESP – BY EXTENDING CASING LENGTH &

CASING HEIGHT

CASING LENGTH EXTENSION

CASING HEIGHT INCREASE

Providing solutions for a better tomorrow

REFERENCE LIST OF RETROFIT ESPs SUPPLIED BY BHEL

Sl. No. UNIT RATING No. OF UNITS

1. 200 MW & ABOVE 8

2. 100 MW to 120 MW 45

3. LESS THAN 100 MW 48

4. INDUSTRIAL BOILERS 31

5. CEMENT & MAGNESITE 14

6. IRON & STEEL 3

7. CHEMICAL RECOVERY 3

TOTAL 152

ARECA ii Latest BHEL’s micro controller for ESP

Features Integrated controller with rapping control

Faster optimisation

Wireless Communication for IOS

Motor on & off command from the Areca ii controller.

Only two wire communication to link the controllers with the

IntelliRelay and IntelliBuffer cards

On any field failure, rapping operation will be continued with the

respective Program Set number

Redundancy can be provided for IntelliRelay card

Remote monitoring and control is provided in IOS PC using

wireless / serial communication

Areca-ii BHEL’s micro controller for ESP

It improves ESP performance by:

Increased agglomeration of

finer fly ash particles

Increase moisture absorption on

the dust particle, particle

cohesion and there by reduces

electrical resistivity of fly ash

Improved electrical operating

properties of ESP fields.

Ammonia Flue gas conditioning system

Providing solutions for a better tomorrow

Bag filter designed and supplied by BHEL

Sl. No. PROJECTS APPLICATION

1. BHEL, HARDWAR FUME EXTRACTION SYSTEM

FOR STEEL FURNACES

2. KORADI, UNIT -5 210 MW- THERMAL POWER

PLANT

3. ISPAT SIDEX, ROMANIA STEEL PLANT

4.

KONIAMBO NICKEL,

NEW CALIDONIA

3X135MW CFBC BOILER

Technical and economic challenges:

Technical challenges:

Space constraints. It involves dismantling & relocating / rerouting existing facilities like pipe & cable racks, steam piping.

Dismantling of duct support columns and providing temporary supports

Strengthening of supporting structures to take care of wind loads seismic loads

Foundation design taking care of specific site constraints like nearest foundation, ash slurry trenches

Erection of ESP in limited space available by employing tower type cranes.

Flow distribution among existing ESP and new ESP pass installed in parallel

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Technical and economic challenges:

Economic challenges:

Unit generation loss when ESP pass is isolated for

up gradation due to Unit running at partial load .

It involves dismantling & relocating / rerouting

existing facilities like pipe & cable racks, steam

piping.

Dismantling & construction of ESP control room in

new location to provide space for Additional ESP

Upgradation of ID fan in case of ESP addition in

series

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ESP – Flow Model Study

Flow distribution ensures by conducting

physical flow model study

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ESP– CFD Model Study

Flow distribution ensures by conducting CFD model

study

BHEL is capable of meeting the new MOEF norms of particulate

emission level below 30mg/Nm3

Conclusion

Thank

You

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