Dantherm - Fluegas Treatment

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Dantherm Filtration

flue gas cleaning for power generation and waste treatment plant

Dantherm presentation

Presented by

Anon Sukman


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Introduction Legislation in Germany

German Legislation:

(17. BIMSCH)

SO2: < 50 mg/m (N)

HCl: < 5 mg/m (N)

HF: < 1 mg/m (N)

Dust: < 5 mg/m (N)

Total heavy metals:


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Introduction

Dantherm Filtration has developed different prozesses for flue gas treatment.The target of all flue gas treatment systems are:

Insuring the necessary clean gas level as requested by the authoroties Minimising investment and complexibility of the system High relaibility by a system as simple as possible Minimising the usage of additives

Allowing different kind of additives depending on the requirements andtotal cost

All systems offered by DTF are based on the flat bag filter technology asdeveloped by DTF more than 30 years ago.


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Development of flue gas treatment in Germany

Start of use 1970 to 1980 1980 to 1990 1988 to 1990 1990 to now 1990 to now 1990 to now

Process/Technology complex scrubber dry sorption dry sorption

semi dry

sorption dry sorption dry sorption

lime injection with conditioning by sprayabsorption with conditioning bicarbonateinjectionand bag filter lime injection

and bag filterand bag filter and recirculation,

lime injection andbag filter

and bag filter

Additive in use CaO Ca(OH)2 Ca(OH)2 CaO / Ca(OH)2 Ca(OH)2 NaHCO3

EfficiencySO2 removal % 90 70 to 75 75 to 80 85 to 90 95 95HCL removal % 99 98 99 99 99 99

Criteria

Investment - - - + + + - - - + + + +Additive cost + + + - - - + - -

Disposal of additives cost + + - - - - - - - +

Operating cost - - - + + + + - - + + +realibility + + + + + + + + + +Space requirement - - - + + + + - + + + +

Control ability + + + + + + + + +


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Compare investment cost

SpraySprayabsorbtionabsorbtion

rotating discrotating discwith reactorwith reactor

SpraySprayabsorbtion fixedabsorbtion fixednozzles withnozzles withreactorreactor

DanthermDantherm

RotosorpRotosorp

system withsystem with

recirculationrecirculation

of reacted limeof reacted lime

productsproducts

investmen


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Selection of best available technology

The known and proven systems in Europe are defined by theThe known and proven systems in Europe are defined by theadditve used:additve used:

A)A) Ca(OH)2 or CaOCa(OH)2 or CaOB)B) Natriumbicarbonate NaHCO3 (baking soda)Natriumbicarbonate NaHCO3 (baking soda)

Both systems are widely used and both of them haveBoth systems are widely used and both of them have


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Ca(OH)2 + SO2 CaSO3 + H2O

Ca(OH)2 +2 HCl

Ca(OH)2 + 2 HF

CaCl2 + 2 H2O

CaF2 + 2 H2O

LimeLime based processbased process

Na2CO3 + SO2 + 1/2 O2 Na2SO4 + CO2

2 NaHCO3 Na2CO3 + CO2 + H2Omin. 140 C


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LimeLime based process, additive cost*based process, additive cost*

* *

Ca(OH)2Ca(OH)2 100 Euro/ton100 Euro/ton

DisposalDisposal 100 Euro/ton100 Euro/ton

ConsumptionConsumption total acids x 2total acids x 2

,,

NaHCO3NaHCO3 200 Euro/ton200 Euro/ton

DisposalDisposal 220 Euro/ton220 Euro/ton

ConsumptionConsumption total acids x 2total acids x 2

*cost base: Germany, 2004*cost base: Germany, 2004


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Dantherm process for lime

Ca(OH)2

Gas coolingGas cooling-- optionoption

ReactorReactorwithwithfluidisingfluidisingrotorrotor

DustDustcollector withcollector withremoisturingremoisturing

systemsystem

M

M

combustionand boiler

Gas cooling - opition-


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Dantherm process for BiCar

Gas coolingGas cooling-- optionoption

Static mixerStatic mixerfor particlesfor particlesand gasand gas

DustDustcollectorcollector

Waste

M

M

combustion

and boiler

NaHCO3

Gas cooling - opition-

M

high speed mill


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Need for Gas cooling systems

Lower gas temperature in D/CLower gas temperature in D/C

allows low price bagsallows low price bags

improves efficiency of SOx removalimproves efficiency of SOx removal

improves removal of D/Fimproves removal of D/F

Selection of gas coolingSelection of gas cooling

Water

fluegas

fluegas, aftercooling

fluegas

fluegas, aftercooling

Gas cooling byGas cooling bywater spraywater spray

Gas cooling byGas cooling by

heat exchangerheat exchanger


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Need for Gas cooling systems

Heat

Selection of gas coolingSelection of gas cooling

Target:Target: keep constant temperature in Dust collector 160keep constant temperature in Dust collector 160 CC

Cooling required:Cooling required: 250 down to 160250 down to 160 CC

Criteria

crosscounterflowfluegas/air

vertical withfixed spraynozzles

flue gas with heigh HCl + + + - - dust agglomeration can be avoidedflue gas with heigh Sox - + + + heigh moisture improves Sox removal

Investment - -

Additive injection - +Operating cost + + - -

realibility + + + +Space requirement + + +

Control ability + + -


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ROTOsorp system for flue gas cleaning

Dantherm FiltrationDantherm Filtration


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Filter dust hopper

Gas inlet toreactor

Dust collectorwith bags

Gas outlet to collector

ROTOsorp system for dust fluidisation

ROTOsorp chainrotor for

Dust fluidisation

Filter dust forwaste

Filter dust forrecirculation Double shaft mixer forDouble shaft mixer for

remoisturingremoisturing


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Rotor with chains

during rotation

ROTOsorp chain rotor for flue gas cleaning

Rotor with chains

during still stand


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Open design, no reduction of open area in

flow direction this avoids any additional

pressure drop in the mixing section

Rotation of the chains in flow direction,

dust and lime will be fluidised and

reinjected into the gas stream

ROTOsorp Rotor design

features

ROTOsorp chain rotor for flue gas cleaning

Design of the chain rotor has proven its

ability and function for many years in the

lime and gypsum industry

Since 1997 the system is used for flue gas

cleaning applications ( about 20 systems)


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Layer of liquid

Steam partial pressure = saturation pressure

Partial pressure of steam at particle surface

(improvmend of reaction for SOx treatment)

Gas phase

Lime particleLime particle


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600

700800

900

1000

g/Nm3 SOx- Rohgas

SOx- Reingas

Linear SOx- Roh asEfficiency 94 %

SOx- removal at 140% water

0

100

200

300

400

10:58:05 11:05:17 11:12:29 11:19:41 11:26:53

Zeit

SOx

m

Linear (SOx- Reingas)


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Hydrated Lime microstructure

Traditional hydrated lime WLFRAsorp A WLFRAsorp D SP /Spongiacal

Specific surface of limeSpecific surface of lime


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1. Purpose

DISA employs white hydrated lime (Calcium hydroxide = Ca(OH)2) according to this specification in gas

cleaning plants, especially chemical sorption plants, in order to bind acid crude gas components.

Burnt lime (CaO) and lime stone (CaCO3) are in no way suitable for this application.

2. Definition

White hydrated lime (CaCO3) is won from limestone after burning and slaking; it mainly consists of

calcium hydroxid (Ca(OH)2).3. Requirements DIN 19611

Mercantile form: dry powder

Appearance : white

Loss of drying (105 C) : max. approx. 1 %

Content of Ca(OH)2 : - water soluble min. approx. 85 %

Specification of hydrated Lime

- . .

Grain size : grain on screen 0,090 mm max. approx. 0,5 %grain on screen 0,063 mm max. approx. 2,5 %

grain on screen 0,030 mm max. approx. 15 %

Bulk weight (bulk feeding) : max. approx. 400 g/ccm

Specific surface area : min. approx. 15 m/g

4. Suppliers / Supplied qualities

In the FRG normally a quality according to DIN 19611 is used, offered from all well-known lime suppliers.

The requirements mentioned in point 3 exceed those of DIN 19611, but normally the main producers stickto the qualities delivered.

5. Controls

5.1 Content of water soluble Ca(OH)2; see DIN 19611

5.2 Total content of Ca(OH)2; titratable with HCl against neutral red

5.3 Grain size; grain size determination by means of air breath sieving

5.4 Bulk weight; see DIN 19611

5.5 BET-surface; unusual special determination for lime industry


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Limitation of ROTOsorp process

too high off gas temperatures from boilers (> 220too high off gas temperatures from boilers (> 220C) and highC) and highcontents of HCl (> 1500 mg/m) as this requires too much coolingcontents of HCl (> 1500 mg/m) as this requires too much coolingby water, which increases the total moisture content in flue gas andby water, which increases the total moisture content in flue gas and

especially in recirculated dust. As the CaCl2 is very hygroscopic,especially in recirculated dust. As the CaCl2 is very hygroscopic,high water content in the gases will create strong agglomerationhigh water content in the gases will create strong agglomerationduring the remoisturing and refeeding.during the remoisturing and refeeding.A solution could be to useA solution could be to usethe Dantherm Gas cooling system with heat exchanger flue gas tothe Dantherm Gas cooling system with heat exchanger flue gas to

..

too high concentration of SO2 (> 3000 mg/m) and very low outlettoo high concentration of SO2 (> 3000 mg/m) and very low outletconcentrations at the same time (


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Dantherm Filtration system for BiCar

Dantherm FiltrationDantherm Filtration


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Dry Sorption with Sodium Hydrogen Carbonate

T > 140 C

2NaHCO3

Na2CO3 CO2 H2O

+ +

Thermal activation of sodium hydrogen carbonate

bicarbonate de sodium

avant activation thermique

carbonate de sodium activsodium hydrogen carbonatebefore activation

sodium hydrogen carbonate

after activation


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Big-Bag -

Station

BiCar handling with big bags


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Mixing reactor (static mixer for flue gas and BiCar)


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Supplement additives for D/F

Dioxin treatment withDioxin treatment withactivated carbonactivated carbon


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High porosity

Carbon structure

Activated carbon microstructure

Types of sorption:

Physical adsorption

Chemical sorption


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Specification of activated carbon

Activated carbon componentIn Germany there are in principle two product groups available, which are of basic difference.1) There are the known activated carbons of different manufacturers, which have been developped, modified andsometimes particularly impregnated for certain applications in the chemical and general process technology for

reactions in the gas- and liquid phase.2) In addition a by-product of the lignite coke treatment so-called open-hearth furnace coke HOK (internaldenomination of Messrs. Rheinbraun Braunkohlenkoksstaub BKKS) proved to be suitable for the describedprocess technology. It is a by-product of a mass production and is not refined. The product is even offered as millactivated.For the separation of mercury and PCDD/-F both products proved to be successful. Experiences show, that A-coal

-pore volume. Considering the PCDD/-F-separation the differences are much smaller.The pre-mentioned differences are observable in the consumption quantities resp. in the achievable emissionlevels.

Remark: When using carbonaceous products the danger of fire and explosion has to be taken into

account.

In order to avoid fires of inflammable dusts an inert material, such as e.g. hydrated lime, can be

injected, as thiselement is not combustible (see sep. safety instructions).

There is practically no danger of explosion up to a C-content of 35 weight% (in homogeneous

particle mixture) and an

operating temperature of < 200C .

For further information:

W. Wiemann, DMT Dortmund:

Crude gas cleaning with combustible dusts (VDI-report)


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Carbon additives comparision

Re asons for the select ion of an addit ive type,

comparison of characteris t ics

Gen era l :

Du e to the subject-minded product ion of specia l ac t ivated carbon types as h ighly act ive adsorpt ion agent their qual i ty iscons tant and the m ater ia l character is t ic wi th in nar row specif icat ion l imits are re l iab le . By m eans of var ious dop ing ra tes

specia l character is t ics are adjus ted according to subject .

Ligni te coke du s t as mass product has a w ider d ispers ive band and no sp ecia l character is t ics .

Safety aspects :

Both m ater ia ls require com parable safe ty measures . Th e d is t inguishing f igures to be taken in to account are very s imilar

.

Un der cer ta in condi t ions act ivated carbon can of fer sma l l advantages .

Reduct ion of pol lutant:

In general , both adsorber types are su i table for the separat ion . Dif ferences can especia l ly be found concerning them ercury separat ion capaci ty . Du e to the m ore favourable sur face and pore con tent h igher loads can be achieved with

infer ior res idual par t ic le emiss ions .

Spec if ic costs:

Th e subject-minded prod uct ion of act ivated carbon as h ighly act ive adsorpt ion agent is re la ted to corresponding cos ts ,

represented in pr ice . The m ater ia l pr ice of 1 .500 - 2 .000D M/to is about factor 3 h igher than the pr ice for HOK .Becau se of the bet ter ef fic iency of act ivated carbon in case of the separat ion of Hg at about factor 2 , the u t i l isa t ion of act ivated carbon can lead to the m os t favourable ad di t ive and d ischarge cos ts in case of h igh H g crude ga s charges ( > 1

m g/m ) and low em iss ion levels ( < 0 ,025 mg/m ) .

I n mo s t o f th e cru d e gas c lean in g ap p l ica t ion s HO K p roves to b e th e m os t favou rab le C -ad d i t ive comp on en t .


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Dantherm Filtration standard components

Dantherm FiltrationDantherm Filtrationdust collector systemsdust collector systems


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DTF additive handling and feeding with big bags

Alu plants


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DTF additive handling and feeding

Additive weighing hopper(installed on load cells)

Dosing feeder controlled byfrequency convetor

Low pressure pneumaticconveyour with injector

Alu plants


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Gas Cooler Type KU

DTF cooler with airDTF cooler with air

recirculation,recirculation,

cooler in doublecooler in double

deck arrangementdeck arrangement

withwith

cooling fans withcooling fans with

noise insulationnoise insulation


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Gas Cooler cleaning device

DTF cooler cleaningDTF cooler cleaning

device,device,

automatic systemautomatic system

using chainsusing chains


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for Biomass and waste combustion


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Waste combustion with spray absorption

Process: limeProcess: lime


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Biomass combustion Malchin (near Berlin)


Bi d W t b ti H EKT (B li )


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Biomass and Waste combustion Harpen EKT (Berlin)


Biomass combustion Wilmersdorf (Berlin)


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Process: BiCarProcess: BiCar



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Process: BiCarProcess: BiCar

SO ti t G l t


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SOx sorption at Gypsum plant


SO ti t G l t


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Fluegas cleaning for Gypsum calcination with brown coal burner

Customer: Felswerke

Flow : max. 92 000 m/h i. B. bei max. 159 C

Inlet concentration SO2 : max. 1600 mg/m i.N.trClean gas concentration SO2 : < 350 mg/m i.N.tr (Warranty)Recirculationamount : 20 m/h d.h. ca. 10.000 kg/h

Fresh additiv : max. 135 kg/h, Limehydrate

SOx sorption at Gypsum plant


DTF Ai fl l i f IMCO f


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DTF Air flue gas cleaning for IMCO furnace

DTF gas cooler with noiseDTF gas cooler with noise

abatementabatement

Flue gas volume

before cooler: 52.000 Nm/h

Temperature in : 300C

Temperature out: 125C

Cooler cleaning: automatic

DTF Ai fl l i j t f POLST


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DTF Air flue gas cleaning project for POLST

DTF Ai fl l i j t f POLST


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Customer POLST, Poland

Gascooler type: 2 x KU 722/10,0/ 840/4

Dust collector type: 2 x FS 722 /8,5/1190

Filterfabric: Polyester

Fule gas volume: 135.000 Nm/h

Temperature range: 150 - 230 C

Residual dust content:


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DTF gas coolerDTF gas cooler

DTF dust collectorDTF dust collector



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DTF Air flue gas cleaning project for Trimet; Germany


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Customer Trimet, Germnay

Gas cooler type: 2 x 722/6/504

Including warm air recirculation into building

Dust collector type: 2 x FS 725 /6,0/840

Filterfabric: Polyester

Fule gas volume: 113.000 Am/h

Temperature range: 60 - 120 C

Residual dust content:


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Gas cooler with warmGas cooler with warmair recirculationair recirculation

DanthermDanthermdustdust

collectorscollectors

Dust handling by big bagDust handling by big bagsystemsystem

DTF Air flue gas cleaning for reverb furnace


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g g

DTF dust collectorDTF dust collectorwithwith ROTOsorpROTOsorp

processprocess

Hydro bilder undHydro bilder und

ZeichnungenZeichnungen

with regenerativewith regenerative

burnersburners

Scrap : windowScrap : window

frames with paintframes with paint

Flue gas volume

before cooler/ filter: 45 000 Bm/h = 26,500 Acfm

Temperature in max : 135C = 255 F

Warranty D/F: < 0,1 ng/Nm or 2g/ton scrap

DTF Air flue gas cleaning for reverb furnace


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g g

DTF Air flue gas cleaning with ROTOsorp


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DTF Gas cooler system for Aluminium plant


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Cooler with air recirculationCooler with air recirculation

Cooler with auto cleaning systemCooler with auto cleaning system

Cooler with air recirculationCooler with air recirculation

Lime recirculationLime recirculation

DTF reference plants (selected)


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Dantherm - Fluegas Treatment

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