11 Flue Gas Desulfurization | Air Quality and Stationary ...

using synthetic gas mixtures are considered to be bench scale.&#;

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Spokesmen who affirm that industrial-scale reliability is now available, as well as spokesmen who deny it, often quote the NAE panel&#;s requirement of 1 year of operation at the 100-Mw scale. They argue whether or not this has been acheived in a particular unit, and whether or not the experience in this unit is generally applicable.

Not much attention has been paid to the other important ingredient by the panel as necessary to insure industrial process availability: the requirement that technical and economic data must be available to permit design of full-scale units to meet specific local and regional conditions.

The NAE panel did its work at a time when the chemistry of sulfur oxides scrubbing appeared far simpler than it does today. The panel considered 16 stack gas control procedures. A reflection of the subsequent advance in knowledge is the fact that 10 of the 16 were not represented by presentations at a meeting that EPA held in Atlanta in early November of to review the status of control technology. The Atlanta meeting considered 13 processes, of which 7 were not on the list of the NAE panel.

It should also be remembered that there have been expensive large-scale development failures in sulfur oxide emission control (see Table 11&#;1). One process, limestone injection into a boiler followed by a scrubber, that EPA urged upon utilities as late as early (Walsh ), is no longer being offered for sale.

The record would stand as an indictment of the engineering profession were it not for the fact, now evidient, that the engineer was compelled to press forward into design and construction of scrubbing equipment of unprecedented size in absence of adequate chemical knowledge. Never before had the chemical engineer been asked to treat such a large flow of gas even for a chemistry that was well understood. It is not surprising, therefore, that many of the early disappointments involved failure of large

FGD Recycle Pumps &#; True Cost Investigation

The only exhibitor of FGD recycle pumps at Power-Gen is Duechting.

Company Name

Last Name

First Name

Mobile

Duechting

Vines

Josh

(479)

 668-

Duechting

Wilson

Daniel

(479)

668-

 

 

80,000 MW of limestone FGD recycle pumps will be purchased in India over the next three years. Over 1.5 million MW of these large pumps are continually being operated at power plants around the world. Their  true cost (total cost of ownership) is a substantial percentage of the true cost for electricity production. One reason is the choice of pump energy over fan energy.

 It can be argued that scrubbers using less recycling slurry but more fan energy are a better choice but the coal fired power industry has standardized on the spray tower type of limestone scrubber.  For a MW scrubber the recycled slurry will be as much as 200,000 gpm delivered to the top of a spray tower at a 50-100 ft elevation. This slurry is an abrasive, corrosive combination of gypsum, calcium sulfite and limestone particles along with some residual flyash. The pumps are expected to remain functional for 20 years or more.

The true cost of the pump purchase is impacted by many factors

·         System design: the piping design, pump location, valve resistance, spray tower nozzle type, chloride bleed provisions, requirement for spares and other factors

·         Pump design including initial efficiency, deterioration characteristics, and pump characteristics

·         Energy consumption for the new pump and during the cycle prior to repair

·         Cost of energy

·         Cost of repair parts and frequency of replacement

·         Cost for service

·         Operational factors such as maintenance quality, hours of operation per year etc.

·         Downtime costs

·         Labor rates

·         Related costs such as greater use of limestone or treatment chemicals with varying pump performance

India has adopted specifications with minor modifications which were first written decades ago for projects in the U.S. or Japan. A recent BHEL specification for an FGD system in Bangladesh Is for two generators each 660 MW and each unit with one FGD system. Each FGD system will be provided with five recirculation pump (4 working + 1 standby) which are located inside the Recirculation Pump & Oxidation Blower House.

The specifications for the recirculating pump allow for rubber lining, stainless alloys or silicon carbide materials in contact with the sulfite slurry with a maximum of 27,000 ppm chlorides.

http://www.bhel.com/dynamic_files/tender_files/pdf/BIFPCL%20MAI%20%20FGD%20ARP%20R01.pdf

This worldwide standardization of scrubber designs and pump requirements means that there is ample evidence of true cost of the various pumps which have been utilized and the ability to project true costs for future installations.

True cost is impacted by the location where the pump is manufactured and the location where the pump is repaired. It is also impacted by the service personnel proximity and the option for remote monitoring and support.

Libra Fluid Equipment Co., Ltd is home based in China. It was founded in and provides pumps and parts for various industries. It supplies pump parts for any pump where the patents have expired.  It supplies ceramic, alloy and rubber lined impellers. This has true cost implications. The true cost of a pump purchased from any company without recently patented parts may be reduced with the option of purchasing parts from others such as Libra.

Parts and repair is a major true cost factor. Duechting Pump manufactures pumps in Germany but has regional service centers around the world. Is the true cost greater or the same for pumps supplied in the U.S and Asia? 

KSB is a German based company but purchased GIW and manufactures pumps in the U.S.  

Trillium has multiple manufacturing and service locations.

Continuing evidence based on experience: As suppliers gain additional evidence it can be incorporated. The process is likened to a criminal trial where the supplier is the prosecutor and the jury is the purchaser. The difference is that the jury is periodically asked to review its decision based on new evidence such as life of impellers and casings in this recent case history.

The scrubber recycle pumps in the plant described in the link have operated at a flow rate of 1,310 cubic meters per hour (m3/h), 21.1 meters (m) of head and 630 revolutions per minute (rpm) for nearly 20 years, requiring minimum attention and service. Of course, the mechanical seals were exchanged from time to time. Apart from that, four impellers, one casing cover and some minor components were replaced. An additional 24 pumps are installed in the second scrubber system and other applications in the plant.

https://www.pumpsandsystems.com/pump-materials-wet-flue-gas-desulfurization

There should be separate true cost analyses for each location.  It is particularly important to analyze the cost in India.  A good example is the analysis by SHI FW relative to wet vs dry scrubbers for Indian power plants.

Sumitomo SHI FW has made a detailed analysis comparing CFB scrubbers to wet limestone scrubbers without wallboard quality gypsum production. 

The  lower quality of limestone available, the expected 15-year life for the older plants to which the system may be applied, and the much lower capital cost of the CFB design are key aspects in the determination. Here are the factors and calculations for a 300 MWe  pulverized boiler contained in the linked paper.

If you want to learn more, please visit our website SHANGLISHI.

Additional reading:
Who makes colloidal silica in the US?
Unlocking the Answers: Key Questions to Ask When Ordering Hydraulic Seals

 http://home.mcilvainecompany.com/images/Article_Show_me_the_Money_CFBS_vs_Wet_FGD_Aug19.pdf

Libra provides Ceramic Pumps and Impellers

 

Libra Fluid Equipment Co., Ltd. was founded in and provides pumps and parts  for various industries, such as mining, metallurgy, coal, power, petroleum, chemical, municipal, environmental, etc.

 

As a China-based slurry pump impeller manufacturer, Libra provides a broad range of impellers, including froth pump impeller, medium/light duty pump impeller, sump pump impeller, sand pump impeller and FGD (flue gas desulfurization) pump impeller or customized impellers.

 

It produces its own pump impellers, and also can provide impellers for competitor pumps Libra Fluid does not represent or is not in any way affiliated with original pump manufacturers. As for the slurry pumps, Libra endeavors to &#;only supply parts to the aftermarket where components were originally designed and developed over twenty years ago (which other OEM&#;s have well and truly enjoyed returns to justify the initial product development &#; the reason patents expire after 20 years!).

 

The  aim is to provide end users an alternative supplier and so bring competition back into the pump aftermarket resulting in end users paying fair prices, obtaining realistic lead times, having better product support, and encouraging future product improvements by all OEM&#;s. All companies and end users benefit from competition.&#;

 

Duechting  Ceramic Pumps demonstrate Lowest Cost of Ownership in U.S. Cement Plant

 

Due to its significant corrosive and abrasive characteristics, gypsum slurry is a very difficult medium to handle. An American cement plant with a yearly capacity of about 2 million metric tons has found a good solution for that issue when it installed the first of two scrubber systems in . This application has similar wear characteristics to FGD.

 

The housings of the eight pumps in the limestone slurry cycle are not made from metal materials, but from a special material that was designed specifically for extremely harsh conditions. This material is a mixture of silicon carbide (SiC) and epoxy resin that is poured into precision molds and heat cured to form the pump components. The material must be machined with diamond tools due to it exhibiting a hardness close to that of diamonds. The material is completely impervious to corrosion and exhibits extreme abrasion resistance given its metallic-free composition and high hardness value.

 

The scrubber recycle pumps in this plant have operated at a flow rate of 1,310 cubic meters per hour (m3/h), 21.1 meters (m) of head and 630 revolutions per minute (rpm) for nearly 20 years, requiring minimum attention and service. Of course, the mechanical seals were exchanged from time to time. Apart from that, four impellers, one casing cover and some minor components were replaced. An additional 24 pumps are installed in the second scrubber system and other applications in the plant.

 

https://www.pumpsandsystems.com/pump-materials-wet-flue-gas-desulfurization

 

Sunbo supplies FGD Pumps and Parts from Chinese Factory

 

Sunbo Pump supplies slurry pumps and replacement parts for Warman pumps. It supplies replacement slurry pump parts in High chrome alloy, Rubber (Elastomer) and Polyurethane, e.g. R55,S42 (Neoprene), U01 (Polyurethane), S12 (Butadiene), S21 (Butyl), SO2 (EPDM), SO2 (Haipalun gum), and special materials. Sunbo is headquartered in Shijiazhuang, China. It develops, manufactures and globally markets slurry pumps for delivering aggressive, abrasive, thick, or solid-filled slurries. 

 

Hanhe is a Chinese FGD Pump and Parts Supplier with exports to India

 

Hanhe Pump Co., Limited is a  slurry and dredging pump manufacturer and exporter. With more than 15-year development it has slurry pump design, production, on-site installation, technical support and approved by ISO: certificate. It supplies slurry pump for Weir Pumps but is not associated with Trillium. It is located in Shijiazhuang City, China. It has offices in India at Hanhe Slurry Pumps Solutions D, Maharashtra, India.

 

Background Data in FGD Knowledge Network (free access for power plants)

 

There are 384 articles about pumps in the FGD & DeNOx newsletter

 

1. Pump Hot Topics were Availability and Pump Materials

... FGD and DeNOx NEWSLETTER June No. 350 Pump Hot Topics were Availability and Pump Materials On April 5 pump experts provided alternative views on pump materials but did ...

2. Düchting SICcast® FGD Pump is Abrasion Resistant

... FGD and DeNOx NEWSLETTER January No. 345 Düchting SICcast® FGD Pump is Abrasion Resistant The unique, patented and proven SICcast® FGD slurry pump technology developed ...

.com/fgddenox/subscriber/fgdnl240/FGD%20Pumps.htm

4. Consider Shaft Sealing, Cable Entry, Cooling When Choosing Pumps for FGD Slurries

... FGD and DeNOx NEWSLETTER June No. 350 Pump Hot Topics were Availability and Pump Materials On April 5 pump experts provided alternative views on pump materials but did ...

16. HH 07 01 11 &#;Selecting the Right Pumps and Valves for Flue Gas Desulfurization&#;

... HH 07 01 11 "Selecting the Right Pumps and Valves for Flue Gas Desulfurization" by Dan Ellis, ITT Engineered Valves, Lancaster, PA and Haminder Ahluwalia 

 

Articles in Coal Fired Power Plant Decisions - Intelligence System  (free to power plant owners)

 

 Duechting ceramic pumps demonstrate low cost of ownership in U.S. cement plant

Due to its significant corrosive and abrasive characteristics, gypsum slurry is a very difficult medium to handle. An American cement plant with a yearly capacity of about 2 million metric tons has found a good solution for that issue  Revision Date:  10/23/

BHEL specifications for FGD pumps in Bangladesh project

There are 2 units of each 660 MW and each unit is envisaged with one FGD system. Each FGD system will be provided with 5 numbers of Recirculation pump (4 working + 1 standby) which are located inside the Recirculation Pump & Oxidation Blower House. The specificiations for the FGD recirculating pump allow for rubber lining, stainless alloys or silicon carbide materials in contact with the sulfite slurry with a maximum of 27,000 ppm chlorides. Revision Date:  10/23/

Putzmeister efficiently moving dense coal ash sludge at largest brown coal plant in Europe

Putzmeister provides eco-friendly solutions to waste management and on shore drilling that follow a sustainable and efficient process. Revision Date:  6/27/

John Crane seal maintenance program improves pump cost of ownership in German lignite fired Power Plant

A German power plant experienced premature wear and excessive seal corrosion in its boiler feed circuit and flue gas desulfurization slurry pumps. Revision Date:  6/12/

 

If you are looking for more details, kindly visit Desulfurization Pump Factory.