Acid Gas Scrubber for Multi-Pollutant Reduction

Emission Control and Measurement Workshop March 24-25, 2010

Nicholas Confuorto Belco Technologies Corporation
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Belco Technologies Corporation

Founded in 1968, was part of Foster Wheeler until 1989. Now subsidiary of DuPont. Located in Parsippany, New Jersey Employing about 65 people Worldwide Supplier of Technologies for Controls of Particulate, SOX and NOX emissions. Specializing in reduction of Oil Refinery Emissions. More systems installed and operating than ALL other competitors COMBINED Offering a wide range of solutions to better serve our customers Certified ISO 9001-2000

Reducing Particulate, SOx and NOx in a single vessel The old long train Approach To Pollution Controls
(No Control of Particulate, SOx or NOx during Boiler Bypass)
ESP # 1 FCC

Boiler
ESP # 2 (Particulate) (Particulate)

ReHeat

SCR (NOX)) (NOX

DeSOx (SO2)) (SO2

Stack

Reducing Particulate, SOx and NOx in a single vessel The old long train Approach To Pollution Controls
(No Control of Particulate, SOx or NOx during Boiler Bypass)
ESP # 1 FCC

Boiler
ESP # 2 (Particulate) (Particulate)

ReHeat

SCR (NOX)) (NOX

DeSOx (SO2)) (SO2

Stack

THE OLD APPROACH IS: COSTLY USES TOO MUCH PRECIOUS REFINERY SPACE IS SUBJECT TO TOO MUCH MAINTENANCE AND POSSIBLE DOWN TIME DOES NOT PROVIDE POLLUTION REDUCTION DURING BOILER BYPASS

Reducing Particulate, SOx and NOx in a single vessel The old long train Approach To Pollution Controls
(No Control of Particulate, SOx or NOx during Boiler Bypass)
ESP # 1 FCC

Boiler
ESP # 2 (Particulate) (Particulate)

ReHeat

SCR (NOX)) (NOX

DeSOx (SO2)) (SO2

Stack

The Multi-Pollutant Approach To Pollution Controls

(Pollutants Controlled even during Boiler Bypass)
BELCOs EDV System

FCC

Boiler

Particulate, SOx and NOx combined

Less Space Required Lower Cost Higher Efficiency Highest Flexibility Higher Reliability Full control even during boiler bypass Can change with your requirement
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EDV Wet Scrubbing System

Reducing Particulate, SO2, SO3 and NOx in a single vessel

EDV Wet Scrubbing Advantages

No Mist Formation No Demister No Mist Fallout Plot Area Small Flexible Highly Reliable Highly Efficient Can provide Combined Particulate, SO2, NOx and SO3 Control Non Plugging Nozzles, Vessel & Component Design Handles High Dust Loads. Even FCCU Upsets Highly Reliable Modular & Integral Single System for all pollutants Multi-Staged Collection

EDV Wet Scrubbing Design

Step 1 Flue Gas is quenched and saturated in the Quench Section. Initial reduction of particulate, SO2 and SO3 is achieved in this step

The EDV Quench Section

Designed to fully saturate
gas

Unique design minimizes

Wet/Dry interface Quench Section

Can be designed to allow

the full regenerator temperatures

EDV Wet Scrubbing Design

Step 2

Reduction of SO2 and Primary Particulate Control is achieved in the Absorber Section

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The EDV Absorber Section

Absorber Section

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The EDV Absorber Spray Section

Absorber Spray Section SO2 & PM Removal Liquid / Gas Contact Staged Approach Open Tower Design Self Cleaning No Mist Formation Low Pressure Drop

Absorber Spray Section

Quench

The EDV G Nozzle

Cross-Section

The EDV G Nozzle

Cross-Section

Plan View

Side View

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EDV Wet Scrubbing Design

Step 3

Further reduction of fine particulate (PM 2.5 and below) and further reduction of SO2 / and SO3 is achieved in Filtering Modules

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EDV Wet Scrubbing System

Filtering Modules
(FMs are applicable only to EDV 5000 and 6000 models)

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Multiple Modules in Each Scrubber

Efficient and Reliable Fine Particulate Control

Scrubber Exterior Scrubber Exterior

Scrubber Interior Scrubber Interior

r Hoppe ternal In

Internal Drain Pipe

Gas Inlet
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EDV 5000 Filtering Module

Efficient Fine Particulate Control

Liquid to Spray
Cleaned Gas on to Droplet Separation Cleaned Gas on to Droplet Separation

Fine Particulate Encased in large water droplet

Condensation & Agglomeration of Fine Particulate & Sulfuric Acid Mist

Fine Particulate

Gas Inlet
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EDV Wet Scrubbing

Step 4 Removal of entrained droplets prior to exit through stack

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EDV Wet Scrubbing System

Droplet Separators

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EDV Wet Scrubbing

Step 5 Treatment of Scrubber Purge in Purge Treatment Plant (PTU)

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Purge Treatment Unit

SCRUBBER PURGE Coagulant and/or Flocculent Solution(s)

EDV Wet Scrubbing

CLARIFIER

Liquid Draining to Sump is pumped back to Clarifier

SETTLING BINS
Concrete Pad with Sump Caustic Addition for pH control Caustic Addition for pH control

EFFLUENT DISCHARGE

AIR BLOWER OXIDATION TOWERS

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Purge Treatment Unit

SCRUBBER PURGE Coagulant and/or Flocculent Solution(s)

EDV Wet Scrubbing

Clarifier and settling bin Used For separation of Particulates from purge
Liquid Draining to Sump is pumped back to Clarifier

CLARIFIER

SETTLING BINS
Concrete Pad with Sump Caustic Addition for pH control Caustic Addition for pH control

EFFLUENT DISCHARGE

AIR BLOWER OXIDATION TOWERS

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Purge Treatment Unit

SCRUBBER PURGE Coagulant and/or Flocculent Solution(s)

EDV Wet Scrubbing

CLARIFIER

Oxidation Needed when scrubbing SO2 to convert Sulfites to Sulfates

Liquid Draining to Sump is pumped back to Clarifier

SETTLING BINS
Concrete Pad with Sump Caustic Addition for pH control Caustic Addition for pH control

EFFLUENT DISCHARGE

AIR BLOWER OXIDATION TOWERS

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EDV Purge Treatment Unit (PTU)

Purge Treatment Unit

NOx Reduction with EDV + LoTOxTM -- Low Temperature Oxidation --

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EDV Wet Scrubber with LoTOxTM on FCCU

Water Droplet Separation SO2 & Particulate Removal PM 2.5 Fine Particulate Removal

NOx Removal

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LoTOxTM NOX Reduction Technology

LoTOxTM is sold to refineries worldwide by BELCO under license from The BOC Group Patented Process of Injecting Ozone into gas stream to control NOx. Applied following Quench in EDV Scrubbing System At Saturation Temperature and with proper mixing and residence time Ozone Reacts with NOX to Form N2O5 Contact with liquid droplets Forms Nitric Acid Nitric Acid is Stabilized with Caustic to Form Sodium Nitrate Greater than 90% reduction of NOx is achieved Commercialized in refinery applications. First commercial FCCU application was in May 2006. Many installations since then. Successfully applied to refinery FCCU and many other processes NOT susceptible to plugging, poisoning, masking or deactivation
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EDV Wet Scrubbing Spray Tower for LoTOxTM

Ozone Injection after Quench Conversion to N2O5 Conversion to Nitric Acid Conversion to Sodium Nitrate More than 90% NOx reduction is achieved No problems such as SCR catalyst poisoning, deactivation, sintering and no SO2 to SO3 conversion Able to operate all the time even during boiler bypass
LoTOxTM is sold to refineries worldwide by BELCO under license from The BOC Group

N2O5 Conversion to HNO3 NO, NO2 Conversion to N2O5

LoTOx Injection

Cross-Section of Single Ozone Generator Cell

Oxygen (O2)
Cooling Water

Glass Dielectric

Electric Current

Grounded electrode

Ozone (O3)

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LoTOxTM Ozone Generator

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LoTOxTM data -Medical College of Ohio

Performance of LoTOx System at MCO December 6, 2001 Outlet NOx Setpoint = 5 PPM Changed to 10 PPM
80 70 60 NOx PPM 50 40 30 20 10 Outlet NOx 0
0: 00 0: :00 52 1: :00 44 2: :00 36 3: :00 28 4: :00 20 5: :00 12 6: :00 04 6: :00 56 8: :00 45 9: :15 3 10 7:1 :2 5 11 9:1 :2 5 12 1:1 :1 5 13 3:1 :0 5 13 5:1 :5 5 14 7:1 :4 5 15 9:1 :4 5 16 1:1 :3 5 17 3:1 :2 5 18 5:1 :1 5 19 7:1 :0 5 20 9:1 :0 5 20 1:1 :5 5 21 3:1 :4 5 22 5:1 :3 5 23 7:1 :2 5 9: 15

40000 35000

Inlet NOx

25000

Flue Gas Flow

Flue Gas Temp = 179 - 234 F Scrubber Temp = 75 - 100 F Inlet SOx = 74 - 178 ppm Inlet CO = 150 - 300 ppm

20000 15000 10000 5000 0

Time

Flue Gas Flow, ACFM

30000

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LoTOxTM data Refinery FCCU

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Demonstrated Performance

80

70

60

50

N x (p m O p

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A verage R eactor Tem perature = 153 F S x in = 211 ppm O Flow R ate = 224 scfm A verage N x R oval = 87% O em

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20

10 ppm NOx set point

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0 22:55:12 23:02:24 23:09:36 23:16:48 23:24:00 23:31:12 23:38:24

NO -IN x

Tim e

NO -O x UT

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EDV Wet Scrubbing

Simplified PFD

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CLEAN EDV STACK

GAS OUT

EDV Caustic System PFD

Model 1000
EDV EDV DROPLET SEPARATORS

Model 5000 Model 6000

MAKEUP WATER

FC

(This loop is for EDV 5000, 6000 and 6600 models only)

EDV FILTERING MODULES (for EDV

5000, 6000 and 6600 models only)
EDV ABSORBER EDV QUENCH

(for EDV 5000 and 6000 models only)

pHC

DIRTY FLUE GAS FROM FCC

FC

CAUSTIC
FC
pHC

OVERFLOW DRAINS
LC

FC

SLIPSTREAM TO PURGE TREATMENT UNIT

EMERGENCY OVERFLOW

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CLEAN EDV STACK

GAS OUT

EDV Scrubbing System PFD

EDV DROPLET SEPARATORS

MAKEUP WATER

FC

(This loop is for EDV 5000, 6000 and 6600 models only)

EDV FILTERING MODULES (for EDV

5000, 6000 and 6600 models only)

(for EDV 5000 and 6000 models only)

pHC

EDV ABSORBER

FC

DIRTY FLUE GAS FROM FCC

CAUSTIC
EDV QUENCH

LoTOxTM Injection

FC
pHC

02

03
OZONE GENERATOR

LC FC SLIPSTREAM TO PURGE TREATMENT UNIT

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EDV scrubbing with LoTOxTM Process

Ozone Injection Grid in Quench Section

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Liquid Discharge elimination using the BELCO LABSORBTM System

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LABSORBTM Regenerative SO2 Scrubbing System

Scrubber

Regeneration Plant

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LABSORBTM
Regenerative Wet Scrubbing
Sodium Phosphate Solution (buffer) used to absorb SO2 Buffer is Regenerated and sent back to the absorber to scrub SO2 Only product from regeneration is a concentrated SO2 stream that is then converted to elemental sulfur or sulfuric acid Reduces load on Waste Water Treatment Plant Reduced Reagent Cost (Caustic) Enhanced Recovery (Sulfur)

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LABSORBTM
Regenerative Wet Scrubbing

Basics - Regeneration Side

Buffer Regenerated using Evaporation with low pressure steam Sulfates and heat stable salts formed from SO3 and oxidation of SO2 are removed as a solid by a patented process Less than 3% buffer loss

LABSORBTM
Regenerative Wet Scrubbing
Installed 9 years ago as SRU tail gas treater at a Refinery in Europe Operating on a 40,000 bpsd FCCU in Italy since June 2003 Operating on a 60,000 bpsd FCCU in the USA since October 2004

LABSORBTM Absorber and Full Pre-scrubber

GAS OUT GAS IN From FCCU
Polishing-Scrubber Built inside stack
DROPLET SEPARATORS

Lean Buffer From Regeneration Plant

FC

PRE-SCRUBBER (EDV 6000) 1 1 1 1

FILTERING MODULES

2 2 2 2

Make-Up MakeWater
DROPLET SEPARATORS

3 3

LABSORBTM Regeneration Plant Rich Buffer To Regeneration Plant SO2 to Sulfur Plant
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LC

FC

FC

Pre-Scrubber PrePurge to Clarifier

3 3

LABSORBTM Regeneration Plant (simplified) SINGLE EFFECT EVAPORATION

CONDENSER

RICH BUFFER FROM SCRUBBER

Vapor Liquid Separator EVAPORATOR Condensat e Tank STEAM CONDENSATE COOLER BUFFER TO SULFATE REMOVAL

CW

Recovered SO2 to SRU or Acid Plant

STRIPPER

35 PSIG STEAM

35 PSIG

cw

LEAN BUFFER BACK TO SCRUBBER

STRIPPER CONDENSATE TO SULFATE REMOVAL MIXING TANK 50%NaOH 85% H3PO4

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QUESTIONS?

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