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Air Quality Control Systems

Air Quality
Control Systems
IHI's Flue Gas Treatment Systems offer impressive credentials to our Customers.
Beginning in the 1970's IHI systems have been installed around the world in a variety of
plant configurations and over a wide range of fuels. IHI has set industry standards on many
occasions as "First" or "Largest".
IHI has the ability to optimize Air Quality Control Systems designs through the combination
of our own leading-edge technologies, such as our DeSOx and DeNOx systems, to bring the
best total system solutions to our Customers. These environmental friendly solutions offer
excellent plant performance while minimizing capital and O&M costs. IHI is continuously
Exploring the Engineering Edge to improve our current basket of solutions to the benefit of
our Customers, while developing the next generation of Air Quality Control technologies.

Contents
IHI Air Quality Control Systems 4
Flue Gas DeNOx System 5-7
Flue Gas DeSOx System 8-11

2 3
IHI Air Quality Control Systems Flue Gas DeNOx System
IHI has a rich history with Engineering, Procurement and In 1978, IHI supplied the world’s first
Construction of Air Quality Control Systems (AQCS) in both Honeycomb catalyst based Selective Catalytic
Reduction (SCR) system for a large scale flue
domestic and overseas markets. This experience allows IHI to
gas emission source. Since then, IHI and our
provide our Customers with the most optimal system that
Licensees have provided over 300 DeNOx
delivers to them the benefits of high reliability and outstanding systems around the world.
performance.
Kudamatsu Power Plant No.3 Unit
The Chugoku Electric Power Co., Inc.
700MW Oil Fired Boiler
Gas Flow: 1,900,000 Nm3/h
Commercial Operation: September, 1979

Principle of IHI SCR System


Ammonia is added to the flue gas at appropriate temperature and the gas is led through the catalyst bed, nitrogen
oxides (NOx) are decomposed into harmless nitrogen (N2) and water (H2O).

NH3 Catalyst Stack


4NO+ 4NH3+ O2 → 4N2+ 6H2O
N2, H2O
NO+ NO2+ 2NH3 → 2N2+ 3H2O

Flue Gas SCR


NOx Reactor

Excellent Performance for All Emissions


IHI SCR Catalyst
IHI's capability covers a broad range of Customers needs beyond conventional AQCS for coal fired power plants.
This capability allows us to address a wide variety of fuels and to comply with stringent local regulations on emissions IHI SCR Catalyst is made from metal oxides, mostly titanium oxide,
such as Particulate Matter, SOx, and NOx. IHI systems have been used on plants firing high-sulfur lignite and oil-coke, which are extruded and calcined into a honeycomb shape. The mm
000
and have achieved removal efficiencies of 99.9% for SOx (world's highest efficiency) and in excess of 97% for NOx. X.1
catalyst provides excellent performance, long life and is free from MA

Employing this experience and capability, IHI can provide cutting edge AQCS solutions to comply with the new US clogging by dust in the flue gas.
regulations such as the Mercury & Air Toxics Standards, the Cross-State Air Pollution Rule and so on. IHI offers a series of catalysts suitable for various types of flue gas

150mm
sources and fuels. High quality catalysts can be supplied with the
shortest possible delivery time.
150mm

▲ ▲ ▲
Cell pitch 7.5mm 5.0mm 3.7mm

Suitable catalysts selected, based on flue gas source


Fuel GAS OIL COAL
Boiler DeNox GAH GGH ESP IDF DeSOx GGH BUF Stack
DUST Negligible Negligible~Low Dust Low Dust High Dust
Cooler Reheater
SOx Negligible Low Mid. Low/Mid. Low Mid.
120~180 ppm-dry (0.2~0.3 lb/mmBtu) L-T L-A H-T
Catalyst Type M-1A M-2A CL-3A CH-1A CH-2A
NOx 15~30 ppm-dry (0.05 lb/mmBtu)
(Low Temp. Type) (Middle Temp. Type) (High Temp. Type)
Honeycomb Honeycomb
Catalyst Cell Pitch 2.5mm, 3.3mm, 3.7mm 4.2mm, 5mm, 6mm, 7.5mm 6mm, 7.5mm
30~50mg/m3N (1.9 ~3.1 µlb/Nft3)
Particulate 20g/m N (1,249 µlb/Nft )
3 3

Matter 8~10mg/m3N (0.5~0.6 µlb/Nft3)


Features of IHI SCR System
700~7,000ppm-dry (0.16~16 lb/mmBtu)
SOx 2~420ppm-dry (0.007~1.0 lb/mmBtu) Honeycomb Shape Catalyst achieves high NOx removal efficiency, reduced catalyst and compact SCR design.
Homogeneous Catalyst realizes low aged-deterioration, easy maintenance and low NH3 consumption.
Low Conversion from SO2 to SO3 keeps GAH free from clogging.
Hg Oxidized Hg
Elemental Hg
IHI SCR system is suitable for a wide operating temperature range.
Stable Catalyst Supply is secured.

4 5
SCR Reactor Mercury Oxidation (Capture Method)
The gas flow direction in the reactor, either vertical downward or horizontal, is determined based on the flue gas dust In this process the SCR plays an important role in
Hg0 Hg0
concentration and device layout. oxidizing the element Hg from the boiler outlet. Hg2+
A small amount of the oxidized Hg is removed in HgP
the ESP (Electrostatic Precipitator), while most of
Vertical Down Flow Type oxidized Hg is captured in the FGD. IHI’s SCR system
based on leading-edge technology oxidizes a higher
percentage of Hg, and leads to more efficient Hg Boiler SCR ESP Wet-FGD Stack

capturing from the flue gas.


Hgp Hg2+

Experiences

Taketoyo No. 4 Boiler


Chubu Electric Power Co., Inc.
Gas flow: 1,060,000 Nm3/h
Photo is provided by J-POWER(EPDC)

Isogo New No.1 & 2 Plum Point Energy Station / USA


Electric Power Development Co.,Ltd. (J-POWER) Plum Point Energy Associates, LLC
600MW Coal-fired Boiler 665MW Coal-fired Boiler
IHI DeNOx System Gas Flow: 1,660,000 wet Nm3/h Gas Flow: 2,309,600 wet Nm3/h
Commencement of Operation: New 1 unit 2002 Commencement of Operation: 2010
IHI is a world leader in the design and fabrication of boilers with an experience list totaling over 500 units providing New 2 unit 2009

in excess of 66 GWs of generation. Through this knowledge of boiler design IHI offers Low NOx Burners and our NOx
Preventing Advanced Combustion Technology (INPACT) to lower total NOx production in the boiler. These technologies
when used in combination with our SCR system are capable of lowering NOx emissions by 97% or more.

OFA
NOx
Reduction
1.0 Zone
Low
NOx
Approx. 0.84 Burner
(500ppm)

Approx. 0.58
▲30% (350ppm)
NOx (lb/mmBtu)

0.5 Hekinan Thermal Power Station No. 4 Futtsu Thermal Power Station System
▲60% Approx. 0.25 Chubu Electric Power Co., Inc. Tokyo Electric Power Co., Inc.
(150ppm) 1,000MW Coal-fired Boiler Group No. 4 stages 1 and 2
Gas Flow: 2,800,000 wet Nm3/h Gas Flow: 2,198,400 wet Nm3/h
Commencement of Operation: 2001 Commencement of Operation: 2009
Approx. 0.03
▲90% (15ppm)

Low NOx Burner INPACT Method SCR

6 7
Flue Gas DeSOx System
IHI has been constructing Flue Gas Desulfurization IHI Spray Tower
(FGD) systems for thermal power stations since
1976 and supplied the world’s first single absorber IHI's Desulfurization System can be customized with the absorber tower shape (Cylindrical or
for a 1,000MW class coal fired plant in 1997. IHI Rectangular) selected according to layout and construction requirements from customers.
is currently a world leader in environmental Agitators arrangement and corner design for Rectangular Type Absorber prevent gypsum
protection technology. sedimentation at the bottom corner.

Matsuura Thermal Power station Unit 2 Cylindrical Type Absorber Rectangular Type Absorber
Electric Power Development Co.,Ltd.(J-POWER)
Treated Gas
Fuel: Coal
Treated Gas
Net Capacity: 1,000MW
Gas Volume(dry): 3,047,000Nm3/h Photo is provided by J-POWER(EPDC)
Mist Eliminator
SO2 Conc.(O2=6%): 675.9ppm-dry
DeSOx efficiency: 95.0%

Limestone-Gypsum Process Spray Nozzle

Features: Absorbent is cost effective and recovered gypsum is usable.


Mist Eliminator
Limestone

Flue Gas

Flue Gas
Gas Outlet

Mist Eliminator Silo

Oxidation Air Oxidation Air


Agitator
Recirculation Pump

Agitator

Recirculation Pump
Feeder

Gas Inlet

Dehydrator 1. Simultaneous treatment of desulfurizing, dedusting and oxidizing in one absorber.


Oxidizing Air
Blower
2. Selection of absorber type (Cylindrical or Rectangular) suitable for compact layout.
Absorber Absorbent Slurry Pit
Recirculating
Slurry Pump 3. Adequate Gas Velocity 4. Adequate Slurry Concentration

Gypsum Waste Water Treatment

Filtrate Pit

Desulfurizing, De-dusting and Oxidizing Gypsum Recovery


Flue gas is introduced into the absorber where dust and The liquid discharged from the absorber is fed into the
SO2 are removed by a spray liquid containing limestone. gypsum dehydrator. The gypsum dehydrator lowers
The spray liquid after desulfurization is oxidized by the the water content of the solid to less than 10% and
air injected into the lower slurry storage tank of the separates the gypsum for easy handling while a part
absorber. of the filtrate from the dehydrator is recirculated and
reused for the desulfurization process.
Principle Chemical Reaction

SO2+ CaCO3+ 1/2O2+ 2H2O → CaSO4 • 2H2O+ CO2 High SO2 Removal and Dust Removal Efficiency High SO2 Removal Efficiency
Reduction of Absorber Diameter

8 9
Non-Leak type Gas Gas Heater (GGH) Experiences
Building upon our knowledge and experience with heat Boiler Stack
exchange surfaces as a boiler manufacturer, IHI has
developed a non-leak, forced circulation, separated heat
exchanger type GAS to GAS Heater (GGH). Developed
Heat Extractor Reheater
and commercialized by IHI the GGH improves efficiency
in both the desulfurization and de-dusting system, while
providing flexibility in the system arrangement. Recirculation Pump
FGD FGD
Flow diagram of Non-leakage type GGH
to FGD

Reihoku Power Station Unit 2 (700MW), Hitachinaka Power Plant No.1 Unit (1,000MW)
Kyushu Electric Power Co., Inc Tokyo Elertric Power Company
Sootblower (Completed in 2003) (Completed in 2003)

Heating Surface
(Fin tube Bundle)

from Boiler

Hsinta Power Station Unit 3 & 4 (2 x 550MW), Pulau Seraya Power Station (3 x 250MW),
Taiwan Power Company Power Seraya Ltd.
(Completed in 2002) (Completed in 2005)

Heat Extractor

to Stack

from FGD

Taichung Power Station Unit 9 & 10 (2 x 550MW), Maritsa East 2 Power Station (4 x 177MW),
Reheater Taiwan Power Company TPP Maritsa East 2 EAD
Fin tube of GGH
(Completed in 2005) (Completed in 2009)

10 11
Our Offices Around the World
EUROPE, MIDDLE EAST, AFRICA
LONDON: IHI EUROPE LTD.
2nd Floor, America House,2 America Square, London EC3N 2LU, U.K.
TEL: +44(20)7481-8180 FAX: +44(20)7481-4955
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TEL: +33(1)4643-1493 FAX: +33(1)4637-7869
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(Mailing Address)BP.102.El Biar,Alger,Algerie
TEL: +213-21-924399 FAX: + 213-21-921436
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TEL: +55(21)3806-2150

Information contained in this catalog is that as of Jan. 2015.


Note that specifications, dimensions and appearance contained
in the catalog may be changed without notice for improvement.
Note that the color tone of the product on the catalog may
appear different from that of the actual product for reasons
Energy & Plant Operations attributable to printing.
Note that the addresses may be changed.
Toyosu IHI Bldg., 1-1, Toyosu 3-chome, Koto-ku, Tokyo 135-8710 Japan
TEL:+81(3)6204-7419 FAX: +81(3)6204-8737 All rights reserved, Copyright Ⓒ 2015, IHI Corporation
URL : www.ihi.co.jp/en/index.html 31770-003-11-1501-2000 FXSS(DN564) Printed in Japan

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