Technology Transfer

Flue Gas Monitoring for Coal-fired Thermal Power Plant

July 2010
J-POWER Tachibanawan Thermal Power Plant1,050MWx2Units)

Content of Presentation

Introduction Introduction Air AirQuality Qualityand andEmission EmissionStandards Standards Flue FlueGas GasTreatment TreatmentFacility Facility Flue FlueGas GasMonitoring MonitoringSystem System Manual ManualMeasurement Measurementof ofFlue FlueGas Gas

Program-1: Program-1: Introduction Introduction

INTRODUCTION INTRODUCTION
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:
Stack
Desulfurization draft fan(BUF)

Boiler

DeNOx (SCR) System

Electric precipitator

Induced draft fan Gas air heater Forced draft fan

Gas-gas heater (GGH)

DeSOx (FGD) System

INTRODUCTION INTRODUCTION
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 Japans choice to spend more on environmental protection and energy security.
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INTRODUCTION INTRODUCTION
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.

Program-2: Program-2:
Air Air Quality Quality and and Emission Emission Standards Standards

Regulation

Environmental Survey to Environmental Monitoring

Environmental Quality Standard

Emission Standard

Emission Standard
New value Plant operation

Environmental Environmental Survey Survey

Surveys on the conditions undertaken at the planned power plant

Prediction Predictionand and Evaluation Evaluationof of Impact Impacton on Environment Environment

Countermeasures Countermeasures of ofEnvironmental Environmental Conservation Conservation

Construction Construction

Environmental Environmental Monitoring Monitoring

+
Monitoring Monitoring Exhaust Exhaustgas, gas, Waste Wastewater, water, Sound, Sound,etc etc
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EIA survey

Regulation

Why is the Monitoring of SOx, NOx etc necessary? SOx: NOx:

+ HC
It affects the Human health and 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:

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

Comparison of the Environmental Air Quality Standards

WHO
g/m3 40-60 110-150 150 400 70 -

Pollutant SO2
Annual 24 hr 8 hr 1 hr Annual 24 hr 8 hr 1 hr Annual 24 hr 8 hr 1 hr

World Bank
g/m3 80 150 100 150 50 150 -

TCVN5937-1995

Vietnam
g/m3 300 500 100 400 200 300

Japan
g/m3 (110) (286) (82-123) 100 200 ppm 0.04 0.1 0.04-0.06 -

NO2

SPM

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

Comparison of the Emission Standards for Coal fired Power Plant

Pollutant World Bank Vietnam
TCVN7440-2005

Guaranteed Parameters at Nghi Son 1

425

Japan

SO2 mg/Nm3

2,000 (700 ppm) 100 - 500 t/d 750 (365 ppm, 260 mg/MJ) 50

425

K-Value rule Example of 500MW K: 3.0 600 K:17.5 3,457 411 (700*103 Nm3/h)* 514 (400~700*103 Nm3/h)* 50~100 (>200*103Nm3/h)* 100~200 (40~200*103Nm3/h)* *: Exhaust gas volume

NOx mg/Nm3 Dust mg/Nm3

850

850

170

98.9

Remarks
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EMS

Environmental Management in Thermal Power Plants

Control of facilitys efficiency Control of environmental pollutants Dealing with local residents and government concerning environmental issues O&M of environmental management system

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EMS

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

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EMS

Control of Pollutants Emission gases (SOx, NOx, dust, O2) Water quality (PH, COD, N, P, etc.) Noise Vibration

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Program-3: Program-3: Flue Flue Gas Gas Treatment Treatment Facility Facility

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Flue Gas Treatment Facility

Environmental conservation countermeasures for thermal power plant

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Flue Gas Treatment Facility

Flue gas treatment facility

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Flue Gas Treatment Facility

Flue Gas Treatment System at Matsuura PS (1000MW2u)

Boiler outlet
SO2: 3150 mg/m3 NOx: 620 mg/m3 Dust: 22600 mg/m3

Agreement value
SO2: 283 mg/m3 NOx: 123 mg/m3 Dust: 40 mg/m3

Boiler
ESP
SCR

Stack AH GGH
FGD

GGH

Flue Gas

ESP

SCR

FGD
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Flue Gas Treatment Facility

Dust Removal Technology- ESP

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Flue Gas Treatment Facility

Dust Removal Technology- ESP

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Flue Gas Treatment Facility

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Flue Gas Treatment Facility

SOx Control - FGD System

SOx <50 ppm NOx <36 ppm

Limestone - Gypsum Process DeSOx > 90%

Dust 20-30mg/m3N

BUF

Stack G G H
IDF
SOx 1000 ppm NOx 300 ppm Dust 20 g/m3N Dust 150 mg/m3N

Boiler
SCR AH

130

ESP

FGD

Gypsum Process
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Flue Gas Treatment Facility

SOx Control Dry DeSOx System

Activated Carbon Process >90%

Boiler
SCR AH

ESP

Dry DeSOx Stack

Activated Carbon

SOx 1000 ppm NOx 300 ppm Dust 20g/m3N

Stack Gas SOx 20 ppm NOx 20 ppm Particulate 10 mg/m3N

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Flue Gas Treatment Facility

SOx Control Spray Dryer System

Boiler

ESP

Stack Spray Dry Absorber

FGD Fan

Lime Slaker

ESP

Calcium sulphate

DeSOx > 80~90%

Fly ash, etc.

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Flue Gas Treatment Facility

DeNOx Technology- SCR

Removal efficiency >80%
Inlet NOx 180 ppm NH3 (Ammonia)
NO NO NO NO

Outlet NOx <36 ppm 350

NH3 NH3 NH3 NH3

Catalyst

2 2

H2O H2O H2O

H2O

Reaction on the Catalyst Surface 4NO4NH3O2 4N2 + 6H2O 6NO2 + 8NH3 7N2 + 12H2O

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Flue Gas Treatment Facility

DeSOx Technology- SPRAY TOWER ABSORBER

Removal efficiency >(80% - 90%)

Features
Simple Configuration Aptitude for Large Capacity Low Pressure Loss Clogging Free

Easy Maintenance

Principal reaction in Absorber

SO2 + CaCO3 + 1/2O2
(Limestone)

CaSO42H2O + CO2
(Gypsum)

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Flue Gas Treatment Facility

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Flue Gas Treatment Facility

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Flue Gas Treatment Facility

FGD System for Coal Fired Boiler (Lime stone process)

300 MW FGD 500 MW FGD 700 1000 MW FGD

Isogo #1 & 2 265 MW, Completion: 1976

Matsushima #1 500 MW, Completion: 1981

Reihoku #1 700 MW, Completion: 1995

Ishikawa #1 & 2 156 MW, Completion: 1986

Shin-Onoda #1 & 2 500 MW, Completion: 1986

Matsuura #2 1000 MW, Completion: 1997

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

Tsuruga #1 500 MW, Completion: 1991

Tsuruga #2 700 MW, Completion: 2000

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Program-4: Program-4:
Flue Flue Gas Gas Monitoring Monitoring System System at at Coal Coal Fired Fired Power Power Plant Plant

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Flue Gas Monitoring System

Environmental conservation countermeasures for thermal power plant

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Flue Gas Monitoring System

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

Stack

Non-Dispersive Infrared Absorption Type for SOx & NOx

GGH
MD

FGD

(Maker: HORIBA)

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Flue Gas Monitoring System

Telemeter System of Stack Gas Monitoring at JPOWERs Thermal Power Plant in Japan
Monitoring Device
(Image)

Transmitted Items SO2 , NOx, etc. Stack

Central Control Room at Power Station

Transmitted Items SO2 , NOx Gas Volume

Local Authority
GGH
MD

FGD

Office
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Flue Gas Monitoring System

System Diagram of Air Pollution Monitoring Telemeter System
Environmental Observation Station Central Monitoring Center Data input Data processor Central processing system Console Telemeter mother station equipment Environmental Observation Station Regional Monitoring Center Central Monitoring Center Printer Display board Factories, power stations, etc. Environmental Observation Station Request of cooperation Regional Monitoring Center Administrative order Control desk Evaluation and study of emergency Console Message Printer Table Printer Disk Tape

Via relay station

Information General household

Notification of emergency Municipal government School

Pollution monitoring vehicle

Radio relay station

Mobile measurement vehicle

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Flue Gas Monitoring System

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Program-5: Program-5:
Manual Manual Measurement Measurement of of Flue Flue Gas Gas at at Ninh Ninh Binh Binh TPP TPP

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Manual Measurement of Flue Gas

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 not installed. It is necessary to follow up periodical monitoring, when the stationary automatic device is malfunctioning and it takes long time to repair.

Necessity: Necessity:

Convenience: Convenience:

9Considering the management of flue gas treatment facility based on the EMS, Manual measuring procedure is very useful due to measure flue gas at inlet & outlet of ESP, FGD and so on. 9Manual measurement data of SO2 and NOx are able to use for checking stationary monitoring device.
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Manual Measurement of Flue Gas

Measuring location and items at Ninh Binh TPP

Boiler

ESP

Stack Measuring location: ESP outlet Main items: SO2, NOx, Dust

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Manual Measurement of Flue Gas

Sampling point at ESP outlet

Flue gas Sampling point

Section plan: seen from upper stream of ESP

Duct area: approx. 6.75m2

Duct of ESP outlet

Numbers of samples: 12~16 ponits

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Manual Measurement of Flue Gas

Outline of gas sampling

Measurement of Gas velocity 12~16 points
Following items are to measure in whole measuring points in order to calculate gas flow velocity. zDynamic pressure (Pa) zStatic pressure (Ps) zGas Temp. (Tg)
= C 2 9 .8 h

Decision of sampling points 1~3 points

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

Measurement of pollutants Sampling

Gas is to suck with equivalent speed to the gas velocity Samples/unit/ Dust: 2 SO2: 2 NOx: 2 Moisture: 2

Vg

= 1 . 3

273 Pa + Ps 273 + Tg 769

Gas velocity has to calculate due to decide gas suction speed

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Manual Measurement of Flue Gas

Manual measurement procedure

SO2
Infrared Infrared absorption absorption method method (portable (portable analyzer) analyzer) in in the the field field Manual Manual analysis* analysis* Chemiluminescence Chemiluminescence method method (portable analyzer) in (portable analyzer) in the the field field Manual Manual analysis* analysis* Sampling Sampling with with filter filter paper paper (dust (dust collector) collector) Dust Dust quantity quantity Analysis Analysis in in the the laboratory laboratory
Portable analyzer HORIBA PG-250 (SO2, NOx, O2)

NOx

Dust

Adaptation of the portable analyzer is to evaluate comparing with data of manual analysis
*Manual analysis: sample gas is to analyze in the laboratory
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Manual Measurement of Flue Gas

Example of Maintenance for Portable Analyzer

Maintenance Items Calibration Periodical inspection Exchange of materials Frequency Every measurement (Zero, Span drift) Checking operation of pump, etc: - Every measurement (Main materials) - Mist catcher (every 3 months) - Scrubber (ditto; for NOx meter) - Pump (every year) - NOx converter (every year) Once a year

Overhaul by manufacturer

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

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Manual Measurement of Flue Gas

Example of manual dust monitoring equipment

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Manual Measurement of Flue Gas

Manual gas measurement at stack inlet

Sampling Probe

Manometer

Matsuura Thermal Power Station (Jan. 2003)

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Manual Measurement of Flue Gas

Manual gas measurement (devices)

Moisture absorber

Dust sampling device

SO2 absorber & mist catcher

NOx monitor (HORIBA)

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Manual Measurement of Flue Gas

(Example) Report of measuring result

Measuring condition
Location (Unit number, ESP outlet etc.) Date Time Weather Measuring method

Plant operation conditions

Plant output (kW) Firing coal Coal consumption (t/hr) Contents of sulfur, nitrogen and ash in coal (%) Unburned C in ash (%)

Measurement results
9 Flue gas volume *1 (wet & dry bases m3N/h) 9 Moisture in gas (%) 9 Gas temp. (degree C) 9 O2 conc. (%) 9 SO2 (mg/m3) 9 NOx (mg/m3) 9 Dust (mg/m3)

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

*1: Calculation by Measured gas parameters

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Manual Measurement of Flue Gas

Investigation on a relation between an environmental monitoring result and the exhaust gas condition
Air Monitoring Place Pollutants with high value Weather Data Wind direction Wind velocity Power Station Plant Operation situation Exhaust Gas Condition Weather situation Wind direction Wind velocity

Example of Investigation

Dispersion DispersionCalculation Calculationof ofPollutants Pollutantsfrom fromthe theStack Stack

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Manual Measurement of Flue Gas

Thinking of Evaluation on the Monitoring Data by Dispersion Calculation

Air quality Standard

It is estimated, whether or not the contribution value of Flue Gas influences a present environmental value. Ground Concentration Level It is also necessary, to evaluate the proportion of ground concentration level to the present condition value.

Present Level

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

Thinking of Evaluation on the Monitoring Data by Dispersion Calculation

Present Level Air quality Standard

Ground Concentration 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.
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