Agenda Costs of emissions prevention and control of

Transkript

This project is co-financed by the European Union and
the Republic of Turkey
Bu Proje Avrupa Birliği ve Türkiye Cumhuriyeti
tarafından finanse edilmektedir
Technical Assistance for Better Air Quality by
Transposing the Large Combustion Plants
Directive (TR2010/0327.04-01/001)
Costs of emissions prevention
and control
By Luca Mancuso,
Process Director, Amec Foster Wheeler
Directive (TR2010/0327.04-01/001)
Agenda
Costs of emissions prevention and control of:
• NOx
• SO2
• Particulate Material
Directive (TR2010/0327.04-01/001)
Costs of NOx emissions
prevention and control
Agenda
• NOx
• SO2
DeNOx control
Nitrogen oxides (NOX) formed during
the combustion of fossil fuels are
mainly NO, NO2 and N2O.
NO contributes to over 90 % of the
total NOX in most combustion types
•
Primary measures
– Developed to control NOX
formation and/or reduction in the
boiler
•
Secondary measures
– End-of-pipe techniques to reduce
NOX emissions
• SCR
• SNCR
Directive (TR2010/0327.04-01/001)
DeNOx Primary measures
•
Low NOx Burners
– Low-NOX burners (LNB) modify the means of
introducing air and fuel to delay the mixing,
reduce the availability of oxygen, and reduce
the peak flame temperature.
– LNBs retard the conversion of fuel-bound
nitrogen to NOX and the formation of
thermal NOX, while maintaining high
combustion efficiency. The pressure drop in
air ducts increases, causing more operational
expenses.
– Types:
•
•
•
•
Air-staged low NOX burner
Flue-gas recirculation low NOX burner
Fuel-staged low NOX burner
Last generation of low NOX burners
Directive (TR2010/0327.04-01/001)
Directive (TR2010/0327.04-01/001)
DeNOx Secondary measures
SCR for NOx emission reduction
• Retrofit of SCR (key factors)
– Constructability: site congestion, space, soil conditions,
access roads, seismic and wind requirements
– Available fan capacity
– Allowable pressure drop
– Flow distribution
– Temperature and ammonia mixing requirements
– Cost and schedule
– Tie-in outage timing and duration
Directive (TR2010/0327.04-01/001)
Example of a SCR retrofit
AIG and
Mixers
Turning
Vanes
Dampers
Flow
Rectifier
Future
Catalyst
Initial
Catalyst
Charge
Directive (TR2010/0327.04-01/001)
AIG
and
Mixers
Future
Cataly
st
Initial
Cataly
st
Charg
e
Directive (TR2010/0327.04-01/001)
CASE STUDY - Key Design Bases
• Site location: Turkey, w/o specific constraints for retrofit
modifications
• Coal
– LHV: 4.6 MJ/kg (AR)
– Sulphur: 1%
• Subcritical Pulverised coal power station
• Thermal input ~ 430 MWth
• Net power output ~ 150 MWe
Directive (TR2010/0327.04-01/001)
CASE STUDY - Macro economic assumptions
80.0
Unit
Data
Lignite cost
$/t
15
years
25
Plant life
Financial leverage
% debt
100
Maintenance cost
% of TIC
2%
Load factor
%
80
CO2 emission cost
$/t
0
Inflation Rate
%
constant
70.22
70.0
60.0
33.47
50.0
LCOE, $/MWh
Item
40.0
30.0
Fuel
0.54
8.47
Variable O&M
Fixed O&M
Capital
20.0
27.74
10.0
0.0
PC base case
Lignite: 15 $/t ; Discount rate: 8%
80% capacity factor; Constant $, 2015.
Directive (TR2010/0327.04-01/001)
SCR: expected techno-economic impacts
Item
Unit
Data
$/kWe
120 (1)
Loss of Power Production
kWe
730
Additional 6 inch w.g. flue
gas pressure drop
Anhydrous Ammonia cost
$/t
600
Total: 510 k$/yr
$/m3
5,000
% TIC/yr
1
CAPEX (EPC cost)
Catalyst cost
Maintenance cost
Remark
Total: 18 M$
Total: 560 k$/yr
(20,000 hours of life)
Total: 135 k$/yr
(1) Considering no major constructability contraints
TOTAL CAPEX:
18 M$
TOTAL O&M cost:
1.2 M$/yr
Directive (TR2010/0327.04-01/001)
Levelized Cost Of Electricity (LCOE): +3.4 $/MWh (+4.8%)
80.0
73.60
72.81
33.63
33.63
1.56
1.56
8.77
8.67
70.22
74.40
70.0
60.0
33.47
33.63
LCOE, $/MWh
50.0
40.0
30.0
0.54
8.47
1.56
Fuel
8.88
Variable O&M
Fixed O&M
Capital
20.0
27.74
29.63
28.94
30.32
PC base case
PC + SCR
PC + SCR -40% CAPEX
PC + SCR +40% CAPEX
10.0
0.0
Directive (TR2010/0327.04-01/001)
SNCR: expected techno-economic impacts
Item
Unit
Data
$/kWe
30
Total: 4.5 M$
Loss of Power
Production
kWe
100
Ammonia
Injection system
Anhydrous
Ammonia cost
$/t
600
Total: 510 k$/yr
% TIC/yr
1
Total: 34 k$/yr
CAPEX (EPC cost)
Maintenance cost
Remark
TOTAL CAPEX:
4.5 M$
TOTAL O&M cost:
0.54 M$/yr
Directive (TR2010/0327.04-01/001)
80.0
70.22
71.24
71.05
71.43
33.47
33.49
33.49
33.49
1.02
1.02
1.02
70.0
60.0
LCOE, $/MWh
50.0
40.0
30.0
0.54
8.47
Fuel
Variable O&M
8.54
8.51
8.56
Fixed O&M
Capital
20.0
27.74
28.18
28.02
28.35
PC base case
PC + SNCR
PC + SNCR -40% CAPEX
PC + SNCR +40% CAPEX
10.0
0.0
Directive (TR2010/0327.04-01/001)
DeNOx primary and secondary measures
All costs are case-specific – Large range of variation is possible
Expected SNCR cost:
Expected LNB cost:
Expected SCR cost:
30 $/kWe
30 $/kWe
120 $/kWe
Directive (TR2010/0327.04-01/001)
Clean gas outlet
Costs of PM emissions
prevention and control
Agenda
• NOx
• SO2
Manifold pipes
Tubesheet
Filter bags and
cages
Split-gas baffle
Pulse
header and
pulse valves
Dirty gas inlet
Directive (TR2010/0327.04-01/001)
De-Dusting
•
Two Principles
– Physical barrier: Fabric Filter
– Induced electrostatic charge: ESP
 Sensitive to resistivity of the gas
•
Fabric Filter
–
–
–
–
•
Particulate emission level <5 mg/Nm3
Porous filter surface removes particulates from gas flow
Product build up on filter causes pressure loss
Energy for cleaning of filter
ESP
–
–
–
–
Removal of 99.9% of particles
Charge and gas characteristics determine removal efficiency
Open gas path provides low pressure loss
Energy for charging flue gas
Directive (TR2010/0327.04-01/001)
DESP
WESP
Roof-mounted
T/Rs
Roofmounted
T/Rs
2 or 4
pt
suspen
sion
Roofmounted
gravity
rappers
2 or 4 pt
suspension
Shopassembled
curtains
Continuou
s plate
irrigation
Rigid
discharge
electrodes
Shopassembled
curtains
Effluent
drain
Rigid discharge
electrodes
Directive (TR2010/0327.04-01/001)
Filter for Particulate emission reduction
• Fabric Filter (key features)
– Pulse cleaning equipment
– High degree of customization to meet project
and customer needs
– Shop-Assembled and Modular Designs
– Captures: 99-99.9% for PM down to sub µm
size, vapor Phase SO2, SO3, HCl, Hf, Hg,
dependent on ash composition and
operating conditions
Manifold pipes
Tubesheet
Filter bags and
cages
Split-gas baffle
Pulse
header and
pulse valves
Dirty gas inlet
Clean gas outlet
Directive (TR2010/0327.04-01/001)
Expected Techno-economic impacts
Item
CAPEX (EPC cost)
Unit
Data
$/CFM
10 (1)
Total: 5.6 M$
kWe
880
Additional flue gas
pressure drop
-
-
Negligible
% TIC/yr
1
Total: 42 k$/yr
Other operating costs
Maintenance cost
Remark
(1) Considering no major constructability contraints
TOTAL CAPEX:
5.6 M$
TOTAL O&M cost:
42 k$/yr
Directive (TR2010/0327.04-01/001)
80.0
70.22
71.27
71.02
71.52
33.47
33.67
33.67
33.67
0.54
0.54
0.54
8.60
8.57
8.63
70.0
60.0
LCOE, $/MWh
50.0
40.0
30.0
0.54
8.47
Fuel
Variable O&M
Fixed O&M
Capital
20.0
27.74
28.46
28.24
28.68
PC base case
PC + Fabric Filters
PC + Fabric Filters -40%
CAPEX
PC + Fabric Filters +40%
CAPEX
10.0
0.0
Directive (TR2010/0327.04-01/001)
Comparison of PM control application
Technology
Captures
Capture Level
Dry
Electrostatic
Precipitator
Dry Solid Particulates
95-99.9% for PM down
to 2.5 µm size
Dry Solid Particulate and
Fabric Filter
Wet
Electrostatic
Precipitator
Vapor phase SO2, SO3,
HCl, Hf, Hg, Dioxins,
Furans
Dry Solid Particulates
and H2O droplets, H2SO4
liquid aerosol
Limited to polishing
applications (low inlet
dust loadings )
Outlet Pollutants Expected
Levels
Installed Operating Footprint Maintenance
(in dry stack gas @ Cost Cost Index Index
Items
6% O2)
($/CFM)
down to 20
mg/Nm3
8.0
1.0
1.0
TRs and
rapping system
down to 2
mg/Nm3 for PM
10
0.9
0.8
Bags, cages
and pulse
valves
17
0.6
1.2 (with
effluent
treatment
system)
0.5
TRs and
irrigation
system
99-99.9% for PM down
to sub µm size
Vapor Phase SO2, SO3,
HCl, Hf, Hg dependent
on ash composition
and operating
conditions
75-95% for PM and
aerosols between 10
µm to sub-micron size
down to 2
mg/Nm3 for PM,
H2O droplets,
H2SO4 aerosols
Costs of SO2
emissions prevention
and control
•
•
Directive (TR2010/0327.04-01/001)
Flue Gas Out
Mist
Eliminators
Multiple Spray
Headers
Flue Gas In
Dual Flow Tray
Agenda
• NOx
• SO2
Recycle Tank
Agitators
Oxidation Air
Recycle
Pumps
Desulfurization
•
Primary measures
– Use of a low sulphur fuel or fuel with
basic ash compounds for internal
desulphurisation
– Use of adsorbents in fluidised bed
combustion systems
•
Secondary measures
– Regenerative processes: the spent
sorbent is re-used after thermal or
chemical treatment to produce
concentrated SO2 which is then usually
converted to elemental sulphur.
NOT GENERALLY ATTRACTIVE
– Non-Regenrative processes
GENERAL CHOICE
Directive (TR2010/0327.04-01/001)
Directive (TR2010/0327.04-01/001)
Desulfurization
•
Chemical Reaction
– All commercial technologies are based on a reaction between Calcium and Sulfur
•
Wet Type
– Cooling down of flue gas below water dew point
– Sorbent is limestone based [CaCO3]
– Technology: Wet Scrubber
•
Semi-Dry Type
– Cooling down of flue gas above water dew point
– Sorbent is lime based [CaO]
– Technologies: Spray Dry Absorber or CFB Scrubber
•
Dry
– No cooling of flue gas
– Sorbent is hydrated lime based [Ca(OH)2]
– Technologies: Dry Sorbent Injection
Directive (TR2010/0327.04-01/001)
WFGD for SOx emission reduction
• Retrofit of FGD (key factors)
– Constructability: site congestion, space,
soil conditions, access roads, seismic
– Fuel composition
– Available fan capacity
– Existing site auxiliary and support facilities
– Cost and schedule
– Tie-in outage timing and duration
Directive (TR2010/0327.04-01/001)
Typical flue gas treatment
Directive (TR2010/0327.04-01/001)
Typical flue gas treatment
Air
Absorber
Fabric Filter
Water
Product Discharge
CFB
Boiler Flue
Gas and
Ash
ID Fan
Stack
Lime
Hydrated
Lime Silo
Dry Lime
Hydrator
Lime
Silo
Product
Silo
Recovery
Optional
Directive (TR2010/0327.04-01/001)
WFG: Expected Techno-economic impacts
Item
Unit
Data
$/kWe
270 (1)
Total: 40.5 M$
kWe
1200
Additional 6 inch w.g. flue
gas pressure drop, air fan
for FGD, raw water pump
consumption
Limestone cost
$/t
10
Total: 800 k$/yr
$/m3
0.1
Total: 16 k$/yr
% TIC/yr
1
Total: 304 k$/yr
CAPEX (EPC cost)
Water cost
Maintenance cost
Remark
(1) Considering no particular constructability contraints
TOTAL CAPEX:
40.5 M$
TOTAL O&M cost:
1.1 M$/yr
Directive (TR2010/0327.04-01/001)
80
76.12
77.95
74.30
70.22
70
60
33.74
33.74
33.74
33.47
LCOE, $/MWh
50
40
30
1.31
0.54
9.14
1.31
1.31
9.38
8.90
8.47
Fuel
Variable O&M
Fixed O&M
Capital
20
27.74
31.93
30.34
PC + FGD
PC + FGD -40% CAPEX
33.51
10
0
PC base case
PC + FGD +40% CAPEX
Directive (TR2010/0327.04-01/001)
Technology
and Pollutant
Capture
Capture Level
75-99% for SO2
30-70% for SO3
90-99+% for HCl, HF
10-70% for total Hg (across absorber)
Wet FGD
90-95% for total Hg (with upstream PAC
DSI system
SO2, SO3, HCl, Hf, 20-60% for PM (in addition to DESP)
Hg
0-30% for PM (in addition to FF)
Absorbers with multiple dual flow trays
typically perform at higher end of range.
Open Absorber tower designs typically
perform at lower end of range
75-95% for SO2 up to 1.5% fuel sulfur
90-99% for SO3 up to 1.5% fuel sulfur
75-99+% for HCl, HF
50-70% for total Hg
SO2, SO3, HCl, Hf,
90-95% for total Hg with PAC
Hg, Dioxins,
95-98% for Dioxins and Furans
Furans
99-99.9% for PM down to sub µm size (FF)
Spray Dryer
Absorber
Circulating
Fluidized Bed
Scrubber
75-99% for SO2
90-99+% for SO3
75-99+% for HCl, HF
60-80% for total Hg
SO2, SO3, HCl, Hf, 90-99% for total Hg with PAC
Hg, Dioxins,
Furans
99-99.9% for PM down to sub µm size (FF)
Outlet Pollutants Levels
(in dry stack gas @ 6% O2)
10-200 mg/Nm3 (3-70 ppm) for SO2
10-50 mg/Nm3 (3-15 ppm) for SO3
3 -15 mg/Nm3 (1-7 ppm) for HCl, HF
0.35-0.65 µg/Nm3 for total Hg (with
upstream PAC DSI system)
down to 2 mg/Nm3 for PM (upstream FF)
down to 20 mg/Nm3 for PM (upstream ESP)
60-200 mg/Nm3 (20-70 ppm) for SO2
under 1-3 mg/Nm3 (0.3-1 ppm) for SO3
3 - 15 mg/Nm3 (1-7 ppm) for HCl, HF
0.5 - 1.0 µg/Nm3 for total Hg
0.35-0.65 µg/Nm3 for total Hg (with PAC)
under 1 ng/Nm3 for Dioxins, Furans
down to 2 mg/Nm3 for PM (FF)
60-200 mg/Nm3 (20-70 ppm) for SO2
under 1-3 mg/Nm3 (0.3-1 ppm) for SO3
under 1-15 mg/Nm3 (0.5-7 ppm) for HCl, HF
0.42 - 0.85 µg/Nm3 for total Hg
0.35-0.65 µg/Nm3 for total Hg (with PAC)
under 0.1 ng/Nm3 for Dioxins, Furans
Sorbent Sorbent
and Stoich Cost
Ratio
Index
Limestone
1.0
1.03
Installed Cost
($/kWe)/
Water Use/
Foot Print
Index
270
1.00
1.00
Hydrated
Lime
1.7 - 1.8
6.0
1.3-1.5 with
PCD solids
recycle
Hydrated
Lime
1.3-1.5
150
0.60
0.40
Maintenance Items
Recycle Slurry Pumps
Gypsum
Absorber Slurry Nozzles
Absorber Liners
Scrubber Sludge
Mist Eliminators
(when Gypsum
is not produced)
Crushers, pumps, valves,
belts, mixers, filters,
Liquid Effluent
compressors, and tanks
containing
within limestone prep,
Chlorides,
oxidation, and
Metals
dewatering systems
Motors, compressors
gearboxes, bearings,
nozzle inserts, and rotary
wheels
Pumps, valves, slaker,
agitator, tanks,
compressors within lime
prep and slurry systems
Water nozzles
6.0
160
0.60
0.60
By Product
Ash Slide and Valve
Dry Solid
Containing
CaSO4, CaSO3,
CaO, fuel ash
Dry Solid
Containing
CaSO4, CaO, Hg,
carbon, fuel ash
Directive (TR2010/0327.04-01/001)
Technology
and Pollutant
Capture
Wet FGD
SO2, SO3, HCl,
Hf, Hg
Capture Level
75-99% for SO2
30-70% for SO3
90-99+% for HCl, HF
10-70% for total Hg (across absorber)
90-95% for total Hg (with upstream PAC
DSI system
20-60% for PM (in addition to DESP)
0-30% for PM (in addition to FF)
Absorbers with multiple dual flow trays
typically perform at higher end of range.
Open Absorber tower designs typically
perform at lower end of range
Dry Sorbent
Injection
SO2, SO3, HCl,
Hf, Hg, Dioxins,
Furans
50-75% for SO2
50-90% for SO3
50-95% for HCl, HF
70-95% for total Hg with PAC
90-99.9% for PM
Capture levels very dependent on
sorbent, injection location and PCD
equipment type and performance
Outlet Pollutants Levels
(in dry stack gas @ 6% O2)
10-200 mg/Nm3 (3-70 ppm) for SO2
10-50 mg/Nm3 (3-15 ppm) for SO3
3 -15 mg/Nm3 (1-7 ppm) for HCl, HF
0.35-0.65 µg/Nm3 for total Hg (with
upstream PAC DSI system)
down to 2 mg/Nm3 for PM (upstream FF)
down to 20 mg/Nm3 for PM (upstream
ESP)
60-200 mg/Nm3 (20-70 ppm) for SO2
15-30 mg/Nm3 (5-10 ppm) for SO3
5-15 mg/Nm3 (2-7 ppm) for HCl, HF
0.35-2 µg/Nm3 for total Hg (with PAC)
0.3-2 ng/Nm3 for Dioxins, Furans
2-50 mg/Nm3 for PM (Fabric Filter)
down to 20 mg/Nm3 for PM (ESP)
Outlet levels very dependent on sorbent,
injection location and PCD equipment
type and performance
Sorbent
Sorbent and
Cost
Stoich Ratio
Index
Limestone
1.0
1.03
Installed Cost
($/kWe)/
Water Use/ Maintenance Items
Foot Print
Index
270
1.00
1.00
By Product
Recycle Slurry Pumps
Absorber Slurry
Gypsum
Nozzles
Absorber Liners
Scrubber Sludge
Mist Eliminators
(when Gypsum is
not produced)
Crushers, pumps,
valves, belts, mixers,
Liquid Effluent
filters, compressors,
containing
and tanks within
Chlorides, Metals
limestone prep,
oxidation, and
dewatering systems
Hyd Lime
PAC
6 for Hyd
Lime
Tronna
50 for PAC
SBC
1.5 for
Trona
3-5 for
Individual
Sorbent
45 for SBC
27
0.00
0.10
Dry Sorbent
Dry Solid
pneumatic transport
Containing CaSO4,
system, metering
CaSO3, CaO, Hg,
valve and injection
carbon, fuel ash
lances
Directive (TR2010/0327.04-01/001)
Levelized Cost Of Electricity (LCOE) - SUMMARY
100
90
80
70.22
73.60
76.12
75.69
33.74
33.27
71.27
78.75
LCOE, $/MWh
70
60
50
40
30
33.47
0.54
33.63
1.56
33.67
0.54
Fuel
1.31
9.14
1.29
9.10
2.31
Variable O&M
9.36
Fixed O&M
8.77
8.60
27.74
29.63
28.46
31.93
32.03
33.79
PC base case
PC + SCR
PC + Fabric Filters
PC + FGD
PC + FF + FGD
PC + SCR + FF + FGD
8.47
Capital
20
10
33.30
0
Directive (TR2010/0327.04-01/001)
Summary findings
• Technical solutions are available for retrofitting coal-fired power
plants in Turkey to comply with major EU environmental
policies (IED)
• Pollutant abatement technologies result in higher capital and
operating costs, leading to an increase of the LCOE:
–
+4.8% SCR
–
+1.4% SNCR
–
+1% Fabric Filter
–
+8.4% FGD
Questions?
Directive (TR2010/0327.04-01/001)

Agenda Costs of emissions prevention and control of

Transkript

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