New flue gas desulphurisation process
Intervex – A new process for desulphurisation
of flue gases
Lars Tiberg and Mats Eriksson
Kurzfassung
Intervex – Ein neues Verfahren zur
Rauchgasentschwefelung
Ein neues Verfahren zur Rauchgasentschwefe-
lung wird vorgestellt. In einen Reaktor werden
Rauchgase im Gegenstrom durch ein körniges
Kalksteinbett geleitet. Wasser wird oberhalb
des Bettes gleichmäßig versprüht. Der Kalk-
stein wandert langsam von oben nach unten
und der Grobanteil wird rezirkuliert. Schwe-
feloxide aus dem Rauchgas bilden Calcium-
sulfit und Calciumsulfat und werden mit dem
Wasser ausgewaschen.
Eine erste Pilotanlage für ein 20-MW-Kessel ist
seit mehreren Jahren in Betrieb. Für diese
kann auf interessante Betriebsergebnisse ver-
wiesen werden.
So kann ein hoher Abscheidegrad von Schwe-
fel, Chlor, Fluor und Flugasche bei geringem
Druckverlust festgestellt werden. Der Ausnut-
zungsgrad des Kalksteins liegt bei 75 %. Der
Kalkstein ist preiswert und die Investitionskos-
ten für die Anlage sind niedrig.
VGB PowerTech - Autorenexemplar - © 2011
Authors
Lars Tiberg, Ph. D.
Radscan Intervex AB
Västeras/Sweden
Mats Eriksson
Gällivare/Sweden
90 VGB PowerTech 10/2011
The basic process
In the Intervex desulphurisation process, gran-
ular limestone is used as reactant, water is
sprayed over the granular bed and the flue gas
is led upwards through the bed.
The reaction between limestone, CaCO3 and
sulphur dioxide SO2 takes place in the pres-
ence of water:
CaCO3 + SO2 + 2 · H2O = as heat exchanger, i.e. two parallel reactors
CaSO3 · 2H2O + CO2 (1)
In the presence of oxygen, the calcium sul-
phite will oxidise to calcium sulphate, gyp-
sum:
CaSO3 · 2H2O + ½ O2 = CaSO4 · 2H2O (2)
The oxidation is rapid in acidic environment.-
To avoid that a layer of calcium sulphate is
formed on the limestone, a small content of
chloride ions should be present in the water.
The chloride ions react with the limestone to
form calcium ions in the spray water, and
these calcium ions react with sulphur dioxide
to form calcium sulphite in the water phase:
CaCO3 + 2HCl = reactor, the exit stone was led to a tumbler to
Ca2+ + CO2 + H2O + 2Cl- (3)
SO2 + 3H2O = 2H3O+ + SO32- (4)
2H3O+ + 2Cl- = 2HCl + H2O (5)
Ca2+ + SO32- + 2H2O = CaSO3 · 2H2O (6)
It is obvious that the chloride ion works as a
catalyst as it takes part in the reaction but is
not consumed.
Some calcium sulphate is precipitated on the
limestone granules, therefore it is necessary to
circulate the stone through the bed to remove
this layer.
Development steps
In the classical wet process, limestone is fine-
ly pulverised, which is emulsified in water.
The emulsion meets the flue gases containing
sulphur oxide in a scrubber tower. The reac-
tion takes place in three steps – (1) dissolution
of SO2 gas in water, (2) transport in the water
to the limestone grain and (3) reaction be-
>>> VGB DIGITAL <<<
tween the two. The total reaction is rather
sluggish and the process demands large reac-
tion volumes.
If however, the limestone is just moistened
with water, and the flue gas is led in contact
with it, the reaction will be very fast. We ob-
served this during our development work and
since then, we have tried to design a desul-
phurisation process for this fast reaction.
In our first process, we used a limestone bed
were applied, which alternatively cooled flue
gas and heated combustion air. When the flue
gas was cooled by limestone, a very thin layer
of water condensed on the stone surface, and
in this layer, sulphur oxide contained in the
flue gas immediately formed calcium sulphite,
i.e. gypsum. The process had two functions:
desulphurisation and recovery of heat from
the flue gases. We could regain heat from the
flue gases down to a temperature about 50 °C.
This double function made the process quite
attractive.
In the process, the flue gas was led upwards
through the limestone bed whereas the lime-
stone was transported downwards, creating a
counter flow process. From the bottom of the
wear off sulphite. The cleaned stones were
transported to the top of the reactor and again
fed into the reactor.
A drawback of this process was the limited
capacity of the limestone surface to take up
sulphur dioxide, i.e. a layer of only about 2
micrometer could built up before the stone
was saturated and had to be cleaned. One cu-
bic meter of limestone (5 to 30 mm) would
only take up 6 kg of sulphur dioxide between
the tumbling treatments. The transport and
tumbling of the limestone became too exten-
sive and too costly.
Another problem was designing a process
where flue gas and air were to be alternatively
led through two reactors. During the exchange
of reactors, for a short time, only flue gas was
led into the boiler furnace with an oxygen
shortage which might cause an explosive situ-
ation.
Our second process was designed avoiding the
explosion risk. We called it Rotovex. A number
of reactors were placed in a ring and a rotating
valve in the centre would lead flue gas and

Flexowellelevator
Fresh limestone
M
To container
Figure 1. Flow scheme.
combustion air successively up and down
through the reactors. In this way the leakage of
flue gas into the combustion chamber would
be rather constant never exceeding about
10 %. This process may still be of interest for
large plants, but it has still the drawback of
very big transport volumes of limestone.
In our third process the heat exchange was
abandoned. We sprayed water over the bed, but
sparsely to let the limestone dry up before it
reached the exit. The idea was to get a dry
waste that could easily be freed from fly ash
and calcium sulphite – sulphate powder. How-
ever, it was too difficult to avoid that wet ma-
VGB PowerTech - Autorenexemplar - © 2011
terial occasionally reached the outlet and
greatly disturbed waste treatment.
Our forth process seems to be a hit. We have
increased the water spray to get a wet outgoing
material. We introduced a quench before the
limestone reactor to give an even cooling of
the whole reactor. With increasing water flow,
we got more calcium sulphite formation in the
water phase and the transport of the limestone
through the reactor could be reduced to 10 %
of what we had used earlier. F i g u r e 1 shows
a flow scheme of the process.
VGB PowerTech 10/2011 91
LIC
01
M
SO2
01
Flue gas out
Demister
Sleve
M Vibration exit feeder
Spiral dewaterer
M M
M
Buffer tank
To container
Counter flow reactor design
The advantages of counter flow processes are
well known to chemists and physicists. The
incoming, most active reagents meet the out-
going product to be cleaned, i.e. very low con-
tents of contaminants can be reached. The
outgoing reagents meet the flue gas with the
highest content of contaminants whereby the
reagents will be fully used up.
Our Intervex reactor ( F i g u r e 2 ) has a coni-
cal bottom part, a cylindrical middle part and a
conical top. Limestone is fed from a top hop-
per through a central feed tube that extends
around 2 meters down in the reactor. From the
tube end, the stone material flows down to
form a cone with a slide angle of around 38
degrees to the horizontal plane. The flue gas is
introduced from a ring chamber around the
bottom end of the cylindrical middle part of the
reactor. From the ring chamber, a number of
ducts extend towards the centre of the reactor
like spokes in a wheel. The ducts are simply
steel plates that are bent in an angle of around
60 degrees with the angle upwards and they are
open downwards. The flue gas can flow from
>>> VGB DIGITAL <<<
New flue gas desulphurisation process
Flue gas in
Quench
LIC Fresh
water
02 M
M
M
Limestone 1-5 mm
To container
LIC
01 Fresh
water
Centrifuge
M
M
To water cleaning
the ring chamber towards the centre and they
can flow from the ducts out in the stone bed
and upwards towards the bed surface. As the
ducts are mounted parallel to the upper conical
bed surface, the distance from the ducts to the
surface is constant over the cross section of the
reactor. As a consequence, the gas velocity will
also be constant over the cross section of the
reactor. The reaction zone extends from the
spokes up to the conical top surface.
The limestone material is slowly transported
down through the reactor. The velocity is con-
trolled by the exit feeder. A set of concentric
funnels in the bottom cone under the spokes
guides the stones to make the downward flow
velocity equal over the reactor cross section.
The material coming out from the bottom is
sieved to three fractions: the finest material <
1 mm goes to the waste treatment, stones 1 to
5 mm are taken out from the process and
stones > 5 mm are again transported to the top
of the reactor.
Water is spayed over the bed via a number of
nozzles that distribute the water evenly over
the stone bed.
We have tested several stainless steel grades in
the reactor. For the ring chamber and spokes,
 New flue gas desulphurisation process

15200

13000

4400
3200

Quench
37821

4000

11101
Figure 2. The Intervex reactor.

Figure 4. Section 13 m reactor.

Figure 3. The Gällivare Intervex plant.
high alloy steels are necessary, but for the
inside of the reactor, including the funnels,
lower alloyed grades are sufficient.
With an even gas flow upward and an even
stone flow and water flow downwards, our In-
tervex reactor gives optimum conditions for a
high contaminant reduction and a high yield
of the reagents. Not only sulphur, but also
VGB PowerTech - Autorenexemplar - © 2011
hance oxidation. Some waste limestone is in fluid. The fluid is reused as spray water. From
the form of stones < 5 mm and some in the the bottom end, a rather thick sludge is pumped
form of a fine powder. The stone is sieved to the dry fly ash container where it is used to
away and can be reused in other processes. All moisten fly ash when it is to be transported to
other wastes come as sludge. We have tested the ash deposit.
two methods to take care of it.
Alternatively, the sludge is dewatered in a cen-
In one method which is used in Gällivare, we trifuge. The dry product will contain around
pump the sludge to a sedimentation tank. 15 % of water. The dewatered product can be
From the top end we take out a rather clean used in concrete production.
Table 1. Technical data for intervex desulphurisation plants.
Gällivare 20 MW peat 200 MW coal
Gas flow Nm3/s 14 92
SO2 contents mg/Nm 3
500 1500
Fly ash contents m/Nm3g 100 150

chlorides, fluorides and fly ash are reduced to

Reactor diameter m 5,8 15
low levels.
Bed depth m 2,5 3,5
Pressure drop quench Pa 300 300
Waste treatment
Pressure drop reactor pA 550 650
3
Exit SO2 contents mg/Nm 9 25
The waste from the process consists of fly ash,
Exit fly ash contents mg/Nm3 7 7
calcium sulphite, calcium sulphate and lime-
3
stone fine material. From the outlet under the Spray flow m /h 16 106
reactor, limestone and waste material pass a Stone flow m3/h 1 20
vibrating feeder with ample air contact where Water consumption m3 /h 2,5 16,5
most of the calcium sulphite is oxidised to cal-
Limestone consumption kg/h 54 1060
cium sulphate (gypsum). A small, acidic bleed
Limestone yield % 75 75
off the quench is pumped to the feeder to en-

92 VGB PowerTech 10/2011

>>> VGB DIGITAL <<<
 New flue gas desulphurisation process

In 2009 we also made a test on completion will not need an electrostatic precipitator. A
The Gällivare plant – results when the plant was operated for 20 days with cyclone or a falling chamber will be suffi-
a strict control of the performance. The fol- cient.
lowing results were documented: The waste sludge will most often be dewatered
In 2002, we started building an Intervex plant
in Gällivare in northern Sweden for a 20 MW Flue gas flow 9 to 11 Nm /s 3 in a centrifuge instead of the sedimentation
peat-fired boiler. Gällivare is situated 100 km Contents of SO2 200 to 400 mg/Nm3 process.
north of the polar circle which means long Degree of desulphurisation 97.5 % F i g u r e 4 shows a drawing of a 13 m reactor
transports routes, long winters and sometimes (for a 160 MW coal boiler).
Availability 97.4 %
very cold weather. The reactor has a diameter We assume a reactor for a 200 MW coal-fired
Limestone yield 55 %
of 5.8 m and is designed for a flue gas flow of boiler as maximum size for one unit. It will
14 Nm3/s. At that time we used the concept Reusable
have a diameter of 15 m and a total height of
with restricted water spraying over the lime- limestone 1 to 5 mm 20 %
30 m to the top hopper.
stone reactor bed that would keep the bottom Overall limestone yield 75 %
The following advantages of the Intervex
and exit feed dry. Since then, we have intro- Since the test, Gällivare Heat and Power has process are important:
duced a quench upstream of the Intervex reac- taken over the plant. F i g u r e 3 shows a view
tor and increased water spraying to get a wet −− The reagent – limestone 5 to 30 mm – is
of the plant and Ta b l e 1 provides some cheap compared to caustic lime for the dry
waste product. We have developed the sedi- data.
mentation system for waste and the moisten- processes or the very finely ground lime-
ing system for the dry fly ash. We improved We now regard the process ready for the mar- stone of the wet process.
many components and the reactor design to ket. −− The pressure drop is lower and the electric-
eliminate the risk for clogging. In autumn ity consumption is lower than in other proc-
2009, we made the last, important improve- esses.
The final process −− The investment cost is lower than for most
ments to the reactor and since then the process
has operated according to our specifications, other processes.
although some failures occurred at external Future Intervex plants will differ from the −− High degrees of emission reduction are
components during the last year. Gällivare plant in some ways: future plants reached. □

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VGB PowerTech 10/2011 93

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 VGB PowerTech
International Journal for Electricity and Heat Generation
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Net­work li­cen­se (cor­po­ra­te li­cen­se), VGB mem­bers’
edi­ti­on (In­fo­Ex­pert) and edu­ca­ti­on li­cen­se on re­quest Pos­tal Co­de Ci­ty Count­ry
(pho­ne: +49 201 8128-200).
* Plus VAT. Pho­ne/Fax
Annual update 1) Euro 150.–; 2) Euro 350.–
The update has to be ordered annually. Da­te 1st Sig­na­tu­re

Re­turn by fax or in business envelope with window to Can­cel­la­ti­on: This or­der may be can­cel­led wi­thin 14 days. A no­ti­ce must be
sent to to VGB Po­wer­Tech Ser­vice GmbH wi­thin this pe­ri­od. The deadline will
VGB Po­wer­Tech Ser­vice GmbH be observed by due mailing. I ag­ree to the terms with my 2nd sig­na­tu­re.
Fax No. +49 201 8128-329
In­fo­Ex­pert Da­te 2nd Sig­na­tu­re
 VGB Po­wer­Tech – www.vgb.org
The generation of electricity and the disposal of heat is in all parts of the world a central
topic of technology, economy, politics and daily live. Experts are responsible for the
construction and operation of power plants, their development and monitoring as well
as for various tasks in connection with service and management.
The technical journal VGB PowerTech is a competent and internationally accepted
publication for power plant engineering. It appears with 11 bilingual issues
(German/English) annually. VGB PowerTech informs with technical/scientific papers and
up-to-date news on all important questions of electricity and heat generation.
VGB PowerTech appears with VGB PowerTech Service GmbH, publishing house of
technical-scientific publications.
VGB PowerTech e.V., the German and European technical association, is the publisher.

VGB PowerTech DVD 1990 to 2010:

Digitalised technical papers of VGB Kraftwerkstechnik and VGB PowerTech.
You find the competent technical know-how from 21 years on more than 12,000 pages
VGB Kraftwerkstechnik (German issues until 2000) and the international technical
journal VGB PowerTech (as of 2001) with:
– More than 2300 technical papers,
– All documents in PDF-format (up to the year 2000 for technical reasons as b/w scan),
– Convenient search function in all papers as full-text search and/or deliberate search
for authors and documents titles,
– Navigate quickly to the desired papers with a few mouse clicks.
The VGB PowerTech-DVD is available as single license or multi-user license for
companies, research institutions and authorities.
The single license can be ordered by form and by post/fax or use our online shop
under www.vgb.org.
A quotation for a multi-user license is made on demand.
You can bring up to date your DVD annually with the VGB PowerTech update.
The update has to be ordered annually.

Your contact at VGB PowerTech Service GmbH,

Jürgen Zimander, Phone: +49 201 8128-200, E-Mail: mark@vgb.org

VGB Po­wer­Tech Ser­vice GmbH

P.O. Box 10 39 32
45039 Es­sen
AL­LE­MAG­NE

In­fo­Ex­pert