Acid Gas Scrubber for Multi-Pollutant Reduction - ladco
Acid Gas Scrubber for Multi-Pollutant Reduction - ladco
Acid Gas Scrubber for Multi-Pollutant Reduction - ladco
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<strong>Acid</strong> <strong>Gas</strong> <strong>Scrubber</strong> <strong>for</strong><br />
<strong>Multi</strong>-<strong>Pollutant</strong> <strong>Reduction</strong><br />
Emission Control and Measurement<br />
Workshop<br />
March 24-25, 2010<br />
Nicholas Confuorto<br />
Belco Technologies Corporation<br />
1
Belco Technologies Corporation<br />
Founded in 1968, was part of Foster Wheeler until 1989. Now<br />
subsidiary of DuPont.<br />
Located in Parsippany, New Jersey<br />
Employing about 65 people<br />
Worldwide Supplier of Technologies <strong>for</strong> Controls of Particulate,<br />
SOX and NOX emissions. Specializing in reduction of Oil Refinery<br />
Emissions.<br />
More systems installed and operating than ALL other competitors<br />
“COMBINED”<br />
Offering a wide range of solutions to better serve our customers<br />
Certified ISO 9001-2000<br />
2
Reducing Particulate, SOx and NOx in a single vessel<br />
The old long train Approach To Pollution Controls<br />
FCC<br />
(No Control of Particulate, SOx or NOx during Boiler Bypass)<br />
Boiler<br />
ESP # 1<br />
ESP # 2<br />
(Particulate)<br />
Re-<br />
Heat<br />
SCR<br />
De-<br />
SOx<br />
(NO X ) (SO 2 )<br />
Stack<br />
3
Reducing Particulate, SOx and NOx in a single vessel<br />
The old long train Approach To Pollution Controls<br />
FCC<br />
(No Control of Particulate, SOx or NOx during Boiler Bypass)<br />
Boiler<br />
ESP # 1<br />
ESP # 2<br />
(Particulate)<br />
THE OLD APPROACH IS:<br />
•COSTLY COSTLY<br />
Re-<br />
Heat<br />
SCR<br />
De-<br />
SOx<br />
(NO X ) (SO 2 )<br />
•USES USES TOO MUCH PRECIOUS REFINERY SPACE<br />
•IS IS SUBJECT TO TOO MUCH MAINTENANCE AND POSSIBLE DOWN TIME<br />
•DOES DOES NOT PROVIDE POLLUTION REDUCTION DURING BOILER BYPASS<br />
Stack<br />
4
Reducing Particulate, SOx and NOx in a single vessel<br />
The old long train Approach To Pollution Controls<br />
FCC<br />
(No Control of Particulate, SOx or NOx during Boiler Bypass)<br />
Boiler<br />
ESP # 1<br />
ESP # 2<br />
(Particulate)<br />
Re-<br />
Heat<br />
SCR<br />
De-<br />
SOx<br />
(NO X ) (SO 2 )<br />
The <strong>Multi</strong>-<strong>Pollutant</strong> Approach To Pollution Controls<br />
Stack<br />
(<strong>Pollutant</strong>s Controlled even during Boiler Bypass)<br />
•Less Space Required<br />
FCC<br />
Boiler<br />
BELCO’s<br />
EDV<br />
System<br />
Particulate, SOx and NOx combined<br />
•Lower Cost<br />
•Higher Efficiency<br />
•Highest Flexibility<br />
•Higher Reliability<br />
•Full control even during boiler bypass<br />
•Can change with your requirement<br />
5
EDV ® Wet Scrubbing System<br />
Reducing Particulate, SO 2, SO 3 and NOx in a single vessel
EDV ® Wet Scrubbing Advantages<br />
No Mist Formation<br />
• No Demister<br />
• No Mist Fallout<br />
Plot Area<br />
• Small<br />
• Flexible<br />
Highly Reliable<br />
Highly Efficient<br />
Can provide Combined<br />
Particulate, SO2 , NOx and SO3 Control<br />
Non Plugging<br />
• Nozzles, Vessel &<br />
Component Design<br />
• Handles High Dust<br />
Loads. Even FCCU<br />
Upsets<br />
• Highly Reliable<br />
Modular & Integral<br />
• Single System <strong>for</strong> all<br />
pollutants<br />
• <strong>Multi</strong>-Staged Collection<br />
7
EDV ® Wet Scrubbing Design<br />
Step 1 – Flue <strong>Gas</strong> is quenched and<br />
saturated in the Quench Section.<br />
Initial reduction of particulate, SO 2<br />
and SO 3 is achieved in this step<br />
8
The EDV ® Quench Section<br />
Quench<br />
Section<br />
• Designed to fully saturate<br />
gas<br />
• Unique design minimizes<br />
Wet/Dry interface<br />
• Can be designed to allow<br />
the full regenerator<br />
temperatures<br />
9
EDV ® Wet Scrubbing Design<br />
Step 2 – <strong>Reduction</strong> of SO 2 and Primary<br />
Particulate Control is achieved<br />
in the Absorber Section<br />
10
The EDV ® Absorber Section<br />
Absorber Section<br />
11
The EDV® Absorber Spray Section<br />
Absorber Spray Section<br />
SO2 & PM Removal<br />
Liquid / <strong>Gas</strong> Contact<br />
Staged Approach<br />
Open Tower Design<br />
Self Cleaning<br />
No Mist Formation<br />
Low Pressure Drop<br />
Absorber<br />
Spray<br />
Section<br />
Quench
The EDV ® G ® Nozzle<br />
Cross-Section
The EDV ® G ® Nozzle<br />
Cross-Section
Plan View<br />
Side View<br />
15
EDV ® Wet Scrubbing Design<br />
Step 3 – Further reduction of fine<br />
particulate (PM 2.5 and below)<br />
and further reduction of SO 2 /<br />
and SO 3 is achieved in<br />
Filtering Modules<br />
16
EDV ® Wet Scrubbing System<br />
Filtering Modules<br />
(FM’s are applicable only to EDV<br />
5000 and 6000 models)<br />
17
<strong>Multi</strong>ple Modules in Each <strong>Scrubber</strong><br />
Efficient and Reliable Fine Particulate Control<br />
Internal Drain Pipe<br />
Internal Internal Hopper Hopper<br />
<strong>Gas</strong> Inlet<br />
<strong>Scrubber</strong> Interior<br />
<strong>Scrubber</strong> Exterior<br />
18
EDV ® 5000 Filtering Module<br />
Efficient Fine Particulate Control<br />
Cleaned <strong>Gas</strong> on to<br />
Droplet Separation<br />
Fine Particulate<br />
Encased in large<br />
water droplet<br />
Fine Particulate<br />
<strong>Gas</strong> Inlet<br />
Cleaned <strong>Gas</strong> on to<br />
Droplet Separation<br />
Condensation &<br />
Agglomeration of Fine<br />
Particulate & Sulfuric<br />
<strong>Acid</strong> Mist<br />
Liquid to Spray<br />
19
EDV ® Wet Scrubbing<br />
Step 4 – Removal of entrained droplets<br />
prior to exit through stack<br />
20
EDV ® Wet Scrubbing System<br />
Droplet Separators<br />
21
EDV ® Wet Scrubbing<br />
Step 5 – Treatment of <strong>Scrubber</strong> Purge in<br />
Purge Treatment Plant (PTU)<br />
22
EDV ® Wet<br />
Purge Treatment Unit<br />
SCRUBBER<br />
PURGE<br />
Coagulant and/or<br />
Flocculent<br />
Solution(s)<br />
Wet Scrubbing<br />
Caustic Addition <strong>for</strong> pH control<br />
OXIDATION TOWERS<br />
CLARIFIER<br />
SETTLING BINS<br />
Concrete Pad with Sump<br />
Liquid Draining to<br />
Sump is pumped<br />
back to Clarifier<br />
EFFLUENT<br />
DISCHARGE<br />
AIR BLOWER<br />
23
EDV ® Wet<br />
SCRUBBER<br />
PURGE<br />
Coagulant and/or<br />
Flocculent<br />
Solution(s)<br />
Wet Scrubbing<br />
Purge Treatment Unit<br />
Caustic Addition <strong>for</strong> pH control<br />
OXIDATION TOWERS<br />
CLARIFIER<br />
SETTLING BINS<br />
Clarifier and settling bin<br />
Used For separation of<br />
Particulates from purge<br />
Concrete Pad with Sump<br />
Liquid Draining to<br />
Sump is pumped<br />
back to Clarifier<br />
EFFLUENT<br />
DISCHARGE<br />
AIR BLOWER<br />
24
EDV ® Wet<br />
SCRUBBER<br />
PURGE<br />
Coagulant and/or<br />
Flocculent<br />
Solution(s)<br />
Wet Scrubbing<br />
Purge Treatment Unit<br />
Oxidation Needed<br />
when scrubbing SO2<br />
to convert Sulfites to<br />
Sulfates<br />
Caustic Addition <strong>for</strong> pH control<br />
OXIDATION TOWERS<br />
CLARIFIER<br />
SETTLING BINS<br />
Concrete Pad with Sump<br />
Liquid Draining to<br />
Sump is pumped<br />
back to Clarifier<br />
EFFLUENT<br />
DISCHARGE<br />
AIR BLOWER<br />
25
EDV ® Purge Treatment Unit (PTU)<br />
Purge<br />
Treatment<br />
Unit
NO x <strong>Reduction</strong> with EDV ® + LoTOx TM<br />
-- Low Temperature Oxidation --<br />
27
EDV ® Wet <strong>Scrubber</strong> with LoTO x TM on FCCU<br />
SO 2 & Particulate<br />
Removal<br />
NO x<br />
Removal<br />
Water Droplet<br />
Separation<br />
PM 2.5 Fine<br />
Particulate Removal<br />
28
LoTOx TM NO X <strong>Reduction</strong> Technology<br />
LoTOx TM is sold to refineries worldwide by BELCO ® under license<br />
from The BOC Group<br />
Patented Process of Injecting Ozone into gas stream to control NOx.<br />
Applied following Quench in EDV ® Scrubbing System<br />
At Saturation Temperature and with proper mixing and residence time<br />
Ozone Reacts with NO X to Form N 2O 5<br />
Contact with liquid droplets Forms Nitric <strong>Acid</strong><br />
Nitric <strong>Acid</strong> is Stabilized with Caustic to Form Sodium Nitrate<br />
Greater than 90% reduction of NOx is achieved<br />
Commercialized in refinery applications. First commercial FCCU<br />
application was in May 2006. Many installations since then.<br />
Successfully applied to refinery FCCU and many other processes<br />
NOT susceptible to plugging, poisoning, masking or deactivation<br />
29
EDV ® Wet Scrubbing<br />
Spray Tower <strong>for</strong> LoTO x TM<br />
N2O5 Conversion<br />
to HNO 3<br />
NO, NO 2 Conversion<br />
to N 2O5 LoTOx<br />
Injection<br />
Ozone Injection after Quench<br />
Conversion to N2O5 Conversion to Nitric <strong>Acid</strong><br />
Conversion to Sodium Nitrate<br />
More than 90% NOx reduction<br />
is achieved<br />
No problems such as SCR<br />
catalyst poisoning,<br />
deactivation, sintering and no<br />
SO2 to SO3 conversion<br />
Able to operate all the time<br />
even during boiler bypass<br />
LoTOxTM is sold to refineries worldwide by BELCO ®<br />
under license from The BOC Group
Cross-Section of Single Ozone Generator Cell<br />
Oxygen (O 2)<br />
Electric<br />
Current<br />
Cooling Water<br />
Grounded electrode<br />
Glass<br />
Dielectric<br />
Ozone (O 3)<br />
31
LoTOx TM Ozone Generator<br />
32
LoTOx TM data -Medical College of Ohio<br />
NOx PPM<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
Inlet NOx<br />
Flue <strong>Gas</strong> Flow<br />
Outlet NOx<br />
0:00:00<br />
0:52:00<br />
1:44:00<br />
Per<strong>for</strong>mance of LoTOx System at MCO<br />
December 6, 2001<br />
Outlet NOx Setpoint = 5 PPM Changed to 10 PPM<br />
Flue <strong>Gas</strong> Temp = 179 - 234 F<br />
<strong>Scrubber</strong> Temp = 75 - 100 F<br />
Inlet SOx = 74 - 178 ppm<br />
Inlet CO = 150 - 300 ppm<br />
2:36:00<br />
3:28:00<br />
4:20:00<br />
5:12:00<br />
6:04:00<br />
6:56:00<br />
8:45:15<br />
9:37:15<br />
10:29:15<br />
11:21:15<br />
12:13:15<br />
Time<br />
13:05:15<br />
13:57:15<br />
14:49:15<br />
15:41:15<br />
16:33:15<br />
17:25:15<br />
18:17:15<br />
19:09:15<br />
20:01:15<br />
20:53:15<br />
21:45:15<br />
22:37:15<br />
23:29:15<br />
40000<br />
35000<br />
30000<br />
25000<br />
20000<br />
15000<br />
10000<br />
5000<br />
0<br />
Flue <strong>Gas</strong> Flow, ACFM<br />
33
LoTOx TM data – Refinery FCCU<br />
34
Demonstrated Per<strong>for</strong>mance<br />
NOx (ppm<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
Average Reactor Temperature = 153 F<br />
SOx in = 211 ppm<br />
Flow Rate = 224 scfm<br />
Average NOx Removal = 87%<br />
10 ppm NOx set point<br />
22:55:12 23:02:24 23:09:36 23:16:48 23:24:00 23:31:12 23:38:24<br />
Time<br />
NOx-IN NOx-OUT<br />
35
EDV ® Wet Scrubbing<br />
Simplified PFD<br />
36
MAKEUP<br />
WATER<br />
EDV ® DROPLET<br />
SEPARATORS<br />
FC<br />
EDV ® FILTERING<br />
MODULES (<strong>for</strong> EDV<br />
5000, 6000 and 6600<br />
models only)<br />
EDV ®<br />
EDV<br />
STACK<br />
DIRTY FLUE GAS FROM FCC<br />
OVERFLOW DRAINS<br />
LC<br />
CLEAN GAS OUT<br />
EDV<br />
QUENCH<br />
EMERGENCY OVERFLOW<br />
EDV<br />
ABSORBER<br />
EDV ® Caustic System PFD<br />
Model 1000 Model 5000 Model 6000<br />
(This loop is <strong>for</strong> EDV ® 5000, 6000 and 6600 models only)<br />
(<strong>for</strong> EDV ® 5000 and 6000<br />
models only)<br />
FC<br />
FC<br />
pHC<br />
FC<br />
SLIPSTREAM TO<br />
PURGE TREATMENT UNIT<br />
pHC<br />
CAUSTIC<br />
37
0 2<br />
MAKEUP<br />
WATER<br />
EDV ® DROPLET<br />
SEPARATORS<br />
FC<br />
EDV ® FILTERING<br />
MODULES (<strong>for</strong> EDV<br />
5000, 6000 and 6600<br />
models only)<br />
DIRTY FLUE GAS FROM FCC<br />
LoTOx TM<br />
Injection<br />
OZONE<br />
GENERATOR<br />
EDV ®<br />
EDV<br />
STACK<br />
0 3<br />
LC<br />
CLEAN GAS OUT<br />
EDV<br />
QUENCH<br />
EDV<br />
ABSORBER<br />
EDV ® Scrubbing<br />
System PFD<br />
(This loop is <strong>for</strong> EDV ® 5000, 6000 and 6600 models only)<br />
(<strong>for</strong> EDV ® 5000 and 6000<br />
models only)<br />
FC<br />
FC<br />
pHC<br />
FC<br />
SLIPSTREAM TO<br />
PURGE TREATMENT UNIT<br />
pHC<br />
CAUSTIC<br />
38
EDV ® scrubbing with LoTOx TM Process<br />
Ozone Injection Grid in Quench Section<br />
39
Liquid Discharge elimination using the<br />
BELCO LABSORB TM System<br />
40
LABSORB TM<br />
Regenerative SO 2 Scrubbing System<br />
<strong>Scrubber</strong><br />
Regeneration<br />
Plant<br />
41
LABSORB TM<br />
LABSORB<br />
Regenerative Wet Scrubbing<br />
TM<br />
Sodium Phosphate Solution (“buffer”) used to<br />
absorb SO2 Buffer is Regenerated and sent back to the<br />
absorber to scrub SO2 Only product from regeneration is a<br />
concentrated SO2 stream that is then converted<br />
to elemental sulfur or sulfuric acid<br />
Reduces load on Waste Water Treatment Plant<br />
Reduced Reagent Cost (Caustic)<br />
Enhanced Recovery (Sulfur)<br />
42
LABSORB TM<br />
LABSORB<br />
Regenerative Wet Scrubbing<br />
TM<br />
Basics - Regeneration Side<br />
Buffer Regenerated using Evaporation with low pressure<br />
steam<br />
Sulfates and heat stable salts <strong>for</strong>med from SO 3 and<br />
oxidation of SO 2 are removed as a solid by a patented<br />
process<br />
Less than 3% buffer loss
LABSORB TM<br />
LABSORB<br />
Regenerative Wet Scrubbing<br />
TM<br />
Installed 9 years ago as<br />
SRU tail gas treater at a<br />
Refinery in Europe<br />
Operating on a 40,000<br />
bpsd FCCU in Italy since<br />
June 2003<br />
Operating on a 60,000<br />
bpsd FCCU in the USA<br />
since October 2004
LABSORB TM Absorber and Full Pre-scrubber<br />
Make-Up Make Up<br />
Water<br />
LC<br />
FC<br />
PRE-SCRUBBER<br />
PRE SCRUBBER<br />
(EDV ® 6000)<br />
FILTERING<br />
MODULES<br />
DROPLET<br />
SEPARATORS<br />
GAS IN<br />
From FCCU<br />
Pre-<strong>Scrubber</strong><br />
Pre <strong>Scrubber</strong><br />
Purge to Clarifier<br />
11<br />
33<br />
22<br />
33<br />
GAS<br />
OUT<br />
Polishing-<strong>Scrubber</strong><br />
Polishing <strong>Scrubber</strong><br />
Built inside stack<br />
DROPLET<br />
SEPARATORS<br />
22<br />
Lean Buffer<br />
From Regeneration Plant Plant<br />
11<br />
FC<br />
FC Rich Buffer To<br />
Regeneration Plant<br />
LABSORB TM<br />
Regeneration<br />
Plant<br />
SO 2 to Sulfur<br />
Plant<br />
45
LABSORB TM Regeneration Plant (simplified)<br />
“SINGLE EFFECT” EVAPORATION<br />
RICH BUFFER<br />
FROM<br />
SCRUBBER<br />
35 PSIG STEAM<br />
STEAM<br />
CONDENSATE<br />
BUFFER TO<br />
SULFATE REMOVAL<br />
LEAN BUFFER<br />
BACK TO<br />
SCRUBBER<br />
Condensat<br />
e Tank<br />
EVAPORATOR<br />
MIXING<br />
TANK<br />
Vapor<br />
Liquid<br />
Separator<br />
CONDENSER<br />
50%NaOH<br />
85% H3PO4<br />
STRIPPER<br />
COOLER<br />
CW<br />
cw<br />
35 PSIG<br />
STRIPPER<br />
CONDENSATE TO<br />
SULFATE REMOVAL<br />
Recovered SO 2 to<br />
SRU or <strong>Acid</strong> Plant<br />
46
QUESTIONS?<br />
47
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