Spray Dry Flue Gas Desulfurization Systems

Proven spray drying absorption process reliably provides

SO2 and hazardous air pollutant emissions reduction

abcock & Wilcox Power Generation Group, Inc.

(B&W PGG) has been at the technological
forefront in providing cost-effective solutions to
tough emission control problems for nearly 40
years. Our continued research and commercial
efforts in reducing emissions of nitrogen oxides
(NOX), sulfur oxides (SO2 and SO3), fine particulate
(PM2.5), mercury, acid gases (HCl and HF), and other
hazardous air pollutants (HAPs) have led to many
advancements in air pollution control technology.

Emission Reduction with High

Availability and Reliability
B&W PGG's commitment to providing the best
in emission reduction technology for power
generation continues with our spray dryer flue
gas desulfurization (FGD) systems for controlling
SO2 emissions.
Our first coal-fired spray dryer absorber (SDA)
installations now have more than 28 years of
operating history. We are the exclusive North
American licensee of GEA Process Engineering
A/S, Denmark, for the GEA Niro SDA process. The
two companies also work together worldwide on
specific project opportunities. The first full-scale
application of the GEA Niro SDA process for coalfired boiler emissions control began operation in
the United States (U.S.) in 1980. After nearly 30
years, the process remains globally recognized
by the industry as the spray dry FGD technology
of choice. B&W PGG and GEA Niros continual
record of utility, industrial and cogeneration SDA
projects has achieved a steady, long-term market
dominance.

As the first SDA process demonstrated at full-scale in the U.S., the GEA Niro
SDA technology has proven successful on more than 21,000 MW of utility
and industrial coal-fired boilers as well as more than 80 waste-to-energy
installations worldwide.

SDA Benefits
High SO2 removal efficiency
Integral SO3, HCl, HF, heavy metals and PM2.5
emissions reduction

SDA Features

Low capital cost

Reliable rotary atomization

High system availability

Highest slurry atomizer capacity in the

industry reduces the number of atomizers
to maintain
Low maintenance/high availability
Abrasion and corrosion resistant components
Efficient flue gas dispersion system

Low auxiliary power use

Low operation and maintenance costs
Low fresh water consumption
Inherent oxidized mercury emissions
reduction
Integral consumption of plant waste water
streams for zero liquid discharge operation

No damper or vane adjustments needed to

follow boiler load
Optimal mixing of flue gas and reagent
Maximum atomizer-to-wall spacing
Optimized performance
High solids reagent recycle
Innovative process control
Control of drying conditions to minimize
potential deposition and corrosion
Large SDA chambers
Typical B&W PGG/GEA Niro SDA system installations
operate at 90 to 95 percent SO2 removal eciency,
with some plants running as high as 98 percent. SO3 ,
HCl and HF removal eciencies are normally greater
than 95 percent.

The B&W PGG SDA provides significant turndown to accommodate boiler

load variations while maintaining optimal performance.

The single, centrally located rotary atomizer minimizes the

potential for wall wetting and deposition, which provides
optimum reagent utilization. Its abrasion-resistant
construction and flexible shaft design can tolerate
imbalances and provides reliable, continuous operation
between scheduled maintenance.

Process Provides Efficiency

and Reliability
The heart of the SDA system is the GEA Niro rotary
atomizer used to atomize a mixture of lime and
recycle slurry into a fine spray. The spray droplets
are well distributed and mix with the hot, untreated
flue gas. A series of chemical reactions result in
the removal of SO2, SO3, HCl and HF from the gas,
and the simultaneous evaporation of the water. A
single, central atomizer promotes an even distribution of the fine spray throughout the chamber
while minimizing any potential for wall wetting
and deposition. The alkaline slurry is converted
into a dry, free-flowing powder of calcium/sulfur
compounds. Flyash from the boiler and the dry
reaction products are then collected downstream of
the spray chamber.
A portion of the solids collected downstream of the
absorber are mixed with water (often lower quality
waste water) to form the primary reagent feed to
the atomizer. These solids contain un-reacted lime
and alkaline minerals from the flyash. Fresh lime
slurry is added directly to the atomizer feed to maintain the required level of alkalinity in the feed slurry
to achieve the desired level of SO2 removal. The total
amount of slurry fed to the atomizer is controlled to
maintain the desired outlet temperature. This solids
recycle process reduces the consumption of fresh
reagent and maintains optimal drying performance
in the spray chamber.
The cooled and treated flue gas exits the SDA and
is directed to a particulate collector, typically a
fabric filter. The particulate collector is designed and
operated as an integral part of the acid gas removal
process as the solids continue to react with SO2, SO3,
HCl and HF in the humidified flue gas.

Inlet Flue
Gas (Upper)

Rotary
Atomizer

Central Gas
Disperser

To
Particulate
Collection

Inlet Flue
Gas (Lower)

The unique flue gas dispersion system of the B&W PGG SDA, coupled
with the rotary atomizer, ensures a uniform distribution of slurry and
provides for intimate contact with the flue gas to optimize absorption
eciency and drying in the spray chamber. For large utility boiler
applications (illustrated here), flue gas enters the spray dry absorber
at two locations: the roof gas disperser and the central gas disperser.
Smaller, lower gas flow installations require only a roof gas disperser.

A reagent recycle system reduces lime consumption and enhances drying performance. Also shown is optional flyash pre-collection,
which may be incorporated in the design to yield a readily marketable ash byproduct.

Total-Project Scope Ensures Effective System Performance

Variety of Applications and Options to
Fit Your Needs
B&W PGGs SDA systems are ideal for new steam generation
projects or retrofits to existing plants. We have a strong track
record of integrating SDAs into existing plants with limited
space. The systems can typically be connected and brought
on-line during a brief tie-in outage, thus minimizing
disruption to power generation.
Reagent slurry

Wide variety of fuels

Powder River Basin (PRB) coal

Solids recycle to minimize lime use

Lignite

Lime only to minimize capital cost

Bituminous coal
Refuse derived fuel and municipal solid waste

Flyash
Pre-collection to generate an ash byproduct to market

Biomass

End collection only to minimize hardware and use

ash alkalinity as reagent

Oil
Combustion gas sources

Particulate collector integration

Pulverized coal and Cyclone boilers

Pulse jet fabric filters

Circulating fluidized-bed boilers

Reverse gas fabric filters

Waste and biomass stoker boilers

Electrostatic precipitators

Incinerators

Integrated Particulate Control

Particulate and scrubber reaction byproducts
downstream of the spray dryer absorber can be
collected by either an electrostatic precipitator
(ESP) or a fabric filter. The preferred method is
typically a fabric filter because it serves as an
efficient secondary acid gas reactor and
provides excellent particulate removal.

Adjacent SDAs share a common spare atomizer.

B&W PGGs fabric filter technology includes nearly

45 years of experience in supplying more than 100
installations with reverse gas cleaning or pulse
jet cleaning systems. On electric utility coal-fired
boilers alone, our fabric filter experience includes
more than 8,000 MW of generation capacity in
more than 50 installations. Our technology is
installed on all types of coal-fired boilers and on
a wide range of industrial processes, and includes
some of the largest SDAs and fabric filters in
the world.

Experienced field engineers and technology

experts provide on-going technical support
for service, upgrades and replacement parts.

B&W PGGs SDAs and fabric filter provide an integrated SO2 and particulate removal process.

Count on B&W PGGs Experience

The B&W PGG SDA process effectively reduces emissions,
meeting and exceeding air quality regulations. This FGD
technology has proven successful on utility and industrial
coal-fired boilers with more than 21,000 MW of installed
capacity worldwide in power generation applications.
Many additional installations are controlling emissions
from industrial processes, district heating and waste-toenergy applications.

B&W PGG's total-project scope includes design, procurement, construction

and startup activities to facilitate the eective performance of the entire
system and integration with existing or new emissions control equipment.

B&W PGG sponsors a Users Group meeting, which rotates

among host SDA installations to provide an open forum
for sharing operating experiences and discussing new
developments. We also participate in numerous other
industry forums each year. Our Environmental Aftermarket
Services group visits each SDA installation regularly,
reflecting our continuing commitment to customer
service and product innovation.

Research for Future

Technology Development

To help our customers prepare for future

compliance regulations, respond to
changes in fuel availability, and to improve
our existing technologies, B&W PGG
conducts research at our world-class facility
that features state-of-the-art analytical
equipment. An SDA pilot is included in
the environmental train of a small boiler
simulator that replicates a commercial
boiler. We routinely work with host plants
to demonstrate enhancements to our
existing technologies to reduce operating
costs and drive performance beyond the
initial design requirements.

SDA systems can be eectively retrofitted into sites with limited space
and typically are brought on-line during a brief tie-in outage,
thus minimizing disruption to power generation.

Ease of maintenance is a key benefit of the B&W PGG SDA

process design.

From Concept to Startup

to Aftermarket Support,
B&W PGG Delivers
B&W PGG takes pride in our total-scope
capabilities. Working with us is easy. Our
dedicated team of experienced engineers
will offer the best solutions to your
emission control needs.
B&W PGG provides conceptual design,
detail engineering, equipment supply,
construction (through our subsidiary,
Babcock & Wilcox Construction Co., Inc.),
startup, commissioning and support
services. We have supplied SDA systems
in a variety of contracting arrangements.
Expert project managers oversee project
execution.
Replacement parts, service and upgrades
are also available for all B&W PGG SDA
systems and atomizers. A well-stocked,
domestic parts center provides efficient
delivery of key replacement parts when
needed. Experienced service engineers and
technology specialists provide on-going
technical support.
As air emission regulations become
tougher, we are committed to provide the
best available technology to enhance the
longevity and competitiveness of coal-fired
power plants for many years to come.
Count on us to provide the total-scope
solution for your next emissions control
project.

10

Selected B&W PGG SDA Projects

Kansas City Power & Light, Hawthorn Unit 5
Boiler capacity
550 MW
Scrubber capacity (acfm)
1,904,000
Inlet SO2 concentration (ppm)
330
SO2 emissions rate (lb/MBtu)
0.10
Commercial operation
2001
Fuel
PRB subbituminous coal

Newmont Nevada Energy, TS Power Plant

Boiler capacity
220 MW
Scrubber capacity (acfm)
855,800
Inlet SO2 concentration (ppm)
355
SO2 emissions rate (lb/MBtu)
0.05
Commercial operation
2008
Fuel
PRB subbituminous coal

Wisconsin Public Service, Weston 4

Boiler capacity
595 MW
Scrubber capacity (acfm)
1,925,000
Inlet SO2 concentration (ppm)
550
SO2 emissions rate (lb/MBtu)
0.08
Commercial operation
2008
Fuel
PRB subbituminous coal

Xcel Energy, Hayden

Boiler capacity
Scrubber capacity (acfm)
Inlet SO2 concentration (ppm)
SO2 emissions rate (lb/MBtu)
Commercial operation
Fuel

Xcel Energy, Comanche

Unit 1

Unit 2

184 MW
974,000
445
0.13
1998
Bituminous coal

262 MW
1,216,250
455
0.13
1999
Bituminous coal

Unit 1

Unit 2

Unit 3

Boiler capacity (gross)

360 MW
Scrubber capacity (acfm)
1,535,000
Inlet SO2 concentration (ppm)
580
SO2 emissions rate (lb/MBtu)
0.08
Commercial operation
2008
Fuel
PRB subbituminous coal

365 MW
1,531,000
580
0.08
2008
PRB subbituminous coal

830 MW
3,620,000
580
0.08
2009
PRB subbituminous coal

Black Hills Generation, Wygen

Unit 1

Unit 2

Unit 3

Boiler capacity
90 MW
Scrubber capacity (acfm)
397,391
Inlet SO2 concentration (ppm)
850
SO2 emissions rate (lb/MBtu)
0.153
Commercial operation
2003
Fuel
PRB subbituminous coal

90 MW
466,941
985
0.09
2008
PRB subbituminous coal

100 MW
466,781
985
0.081
2010
PRB subbituminous coal

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B&W PGGs SDA system provides cost-effective emissions reduction

solutions for the existing fleet of both base-loaded and peaking coalfired power plants.
Selection of our SDA technology for new generating capacity projects
continues to demonstrate the viability of the technology to meet even
the most stringent air quality standards.

www.babcock.com

Babcock & Wilcox Power Generation Group, Inc.

20 S. Van Buren Avenue
Barberton, Ohio 44203 USA
Phone: 330.753.4511
Fax: 330.860.1886

Babcock & Wilcox Power Generation Group, Inc. is a subsidiary of

The Babcock & Wilcox Company (B&W). Established in 1867, B&W is
a world leader in providing steam generating and emissions control
equipment, nuclear operations and components, and defense program
management services.

The information contained herein is provided for general information

purposes only and is not intended nor to be construed as a warranty, an
oer, or any representation of contractual or other legal responsibility.

For more information, or a complete listing of our sales and service

oces, call 1-800-BABCOCK (222-2625), send an e-mail to
[email protected], or access our Web site at www.babcock.com.

Cyclone is a trademark of Babcock & Wilcox Power Generation Group, Inc.

2009 Babcock & Wilcox Power Generation Group, Inc.
All rights reserved.

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