De-Sox- DE-SULPHURISATION SYSTEM FOR STEAM BOILER

At Present the industry is using PETCOKE / COAL in their Process/ Power Steam Generators. With abundant availability and relatively cheaper prices Petcoke is becoming the preferred fuel in North India. While Pet coke has lot of advantages like High GCV, Low Ash content, High Bulk density etc., one of the Big deterrents is THE HIGH SULPHUR CONTENT which in certain cases is in the range of 7 – 8 %.

By using High Sulphur fuel In Steam Generators there are several ill effects on environment like ACID rain, poor ambient Air Quality, Ecological imbalance of Marine Life.  With growing global awareness on all of these ill effects, the CENTRAL POLLUTION CONTROL BOARD / NATIONAL GREEN TRIBUNAL is becoming stringent and are revising the emission level of flue gases.

In days to come with these new norms becoming applicable and 24 x 7 ONLINE MONITORING of STACK EMISSION, industry has to comply with these norms and hence the need for RIGHT QUALITY FLUE GAS POLLUTION CONTROL EQUIPMENTS which ensure continuous conformity  to the applicable CPCB norms.

FOR MONITORING of FLUE GAS EMISSIONS FOLLOWING PARAMETERS ARE CONSIDERED.

A ) PARTICULATE MATTER ( SPM ) – ESP / ESP + BAG FILTER for level up to 30 mg/nm3 ( well accepted technology)

B) SOX- Flue Gas De-sulphuriser ( FGD)-   FGD are manufactured by world leading engineering companies like HITACHI, MITSUBISHI, BABCOCK & WILCOX, LODGE COTRELL but all of these companies are addressing more than 500 MW capacity Power plants.

INTRODUCTION OF MAGO THERMAL COMPANY :-

  • We are a GROUP of YOUNG PROFESSIONAL’s  & VIBRANT Engineers engaged in the field of BOILER CUSTOMIZATION & AIR Pollution Control Equipments ( Since2002 Onwards ).
  • We have been working on BIOMASS FUELS  &  100 % PETCOKE Fired Boilers – since this was first introduced in India by RELIANCE INDUSTRIES LIMITED.
  •  In fact we were being RECOMMENDED by RELIANCE INDUSTRIES LIMITED (PETCOKE Marketing Group) to PROSPECTIVE USERS of 100 % Petcoke Fired Boilers – all these Years.
  •  We have had spent Major part of our PROFESSIONAL Careers in companies like THERMAX etc before we took the BUSINESS TRAJECTORY ourselves 2000 onwards.

–  Mago is known and has established itself in the industry with ITS CUSTOMISED design solutions.

–  MAGO’s customers are Goodyear India Limited, PEPSICO India,  Coca Cola, J.K.Tyres, NAHAR Group, Kwality Dairy, ACTION group, Pasupati Acrylon  —  are among OUR VALUED Customers.

THE MANY FIRST INVENTIONS ACCOMPLISHED BY MAGO, SO FAR :-

YEAR 1999- First FBC FURNACE on MUSTARD STRAW WITH PNEUMATIC FEEDING SYSTEM.

YEAR 2002- PETCOKE RETROFITTING WITH IBR PRESSURE PART.

YEAR 2003- PETCOKE COMBUSTION SYSTEM- PRIMARY COMBUSTOR – HIGH VELOCITY AND SECONDARY COMBUSTOR- LOW VELOCITY ZONE.

YEAR 2004- ASH RECIRCULATION OF PETCOKE.

YEAR 2007- INTRODUCTION OF BIOMASS BRIQUETTE FIRED BOILERS IN PEPSICO/ COKE.

YEAR 2007- RETROFITTING OF GAS FIRED D TYPE  STEAM BOILER TO RICE HUSK.

YEAR 2012- COMBUSTION SYSTEM FOR LAKRA LIGNITE ( EXPORT JOB)

YEAR 2015- AUTOMATIC RE-CIRCULATION SYSTEM FOR PETCOKE COMBUSTION.

YEAR 2015- ENGINEERING FOR 55 TPH, 515 DEG C 100 % PETCOKE STEAM BOILER FOR BUBLLING BED.

YEAR 2016- FLUE GAS DESULPHURISERING SYSTEM ( LIME + NAOH BASED)

AND NOW MAGO PROUDLY INTRODUCES THEIR COMMERCIAL VIABLE FGD DESIGN FOR SMALL POWER PLANTS.

MAGO THERMAL is a pioneer in Boiler Retrofitting having range of 2 TPH to 100 TPH , Steam Pressure upto 115 Bar and Super-heat temperature up to 515 Deg C. Mago Thermal Has more than 250 successfully running installation out of which more than 100 steam boiler are running on 100 % Petcoke.

PETCOKE is refinery Bi-Product has very High GCV with less than 1 % Ash. Since year 2000 Indian Industry is using Pet coke for their Process heat and power demand. Pet coke contain high sulphur, in the range of 6 to 8 %. This sulphur is very corrosive and become threat not only for Steam Boiler and its auxiliaries but also damages ECO-ENVIRONMENT. There is strong need to control Air Pollution generated from Boiler /furnaces.

There are following type of Pollutants are generally coming out of stack.

Suspended particles
SOX
NOX
Here MAGO THERMAL has developed unique Mechanism FOR SULPHUR RECOVERY SYSTEM

A- PRIMARY TREATMENT

SULPHUR RECOVERY DURING COMBUSTION ( FURNACE ZONE)

DRY SCRUBBING in POST COMBUSTION ( FREE BOARD ZONE)

B- SECONDARY TREATMENT

Wet FGD with NAOH A-PRIMARY TREATMENT SULPHUR RECOVERY DURING COMBUSTION ( FURNACE ZONE) MAGO THERMAL recommends to use LIME STONE ( CaCO3) along with Bed Material up to 3 to 4 % Fuel in AFBC steam Boiler to capture SO2 with in the Combustion Zone. With 6-7 % Of Sulphur in Fuel total SOX generation is in range of 2000 PPM

Thermal decomposition;

CaCO3(s) + HEAT → CaO(s) + CO2(g)

CaO+SO2⟶CaSO3

DRY SCRUBBING in POST COMBUSTION ( FREE BOARD ZONE). Ca(OH)2 is sprayed in Free Board zone with specially designed nozzles at strategic location to create DRY SCRUBBING ACTION . The Calcium is recovered in the form of zypsum from ESP. BY IMPLIMENTING 1 & 2 System Sox Drops up to 700-1000 PPM range.

Ca(OH)2 + HEAT = CaO. + H2O

CaO+SO2⟶CaSO3

FOR dry sorbent flue gas desulfurization a variety of dry sorbent injection technologies have been developed by MAGO which offer advantages over the wet lime/limestone scrubbers systems which are typically used to scrub power plant flue gases of sulphur dioxide (SO2) today.

MAGO dry scrubbing technologies are more easily retrofitted with Existing Power plants by spending lower capital costs. They rely on complex gas-solid or gas-wet-solid reactions for conversion of gaseous SO2 to solid products, which result in a number of competing and simultaneous reactions which may either hinder or be beneficial to the overall degree of sulfation. Convective pass sorbent injection is the flue gas desulfurization process where Ca(OH)2 is injected in the medium-temperature range of 425–650 Deg C, which usually occurs in the convective tube section of a boiler in the vicinity of the economizer.

B-SECONDARY TREATMENT

Sox 700-1000 PPM laden Flue gases and FLY ASH / UNBRUNT CARBON 8-15 Gm / m3 is passed through Boiler Bank -Convection Bank -Economiser –APH & finally ESP. Unbrunt Carbon gets recirculated for better combustion efficiency and Zypsum is disposed off to Cement industry / Landfilling.

MAGO Flue Gas Desulphurization : Mago Thermal offers world unique Flue Gas Desulphurization (FGD) System with a minimum 95% Sulphur Dioxide (SO2) removal.

SAILENT FEATURES

1.    The system works equally well on low and high inlet Sulphur Dioxide (SO2) concentrations. Even with large variations in the inlet Suphur Dioxide concentrations to the Flue Gas Desulphurization (FGD) system. Flue Gas Desulphurization (FGD) produces an almost constant outlet Sulphur Dioxide (SO2) concentrations. This characteristic of our Flue Gas Desulphurization (FGD) system is due to its operation in the “concentrated absorption chemical mode”. This Flue Gas Desulphurization (FGD) system differs substantially from the other Flue Gas Desulphurization (FGD) processes. The acting chemical in the Flue Gas Desulphurization (FGD) system is Sodium Sulfite. The concentration of dissolved solids in this system is maintained at a much higher level than other conventional system enabling our Flue Gas Desulphurization (FGD) system to have low recirculating liquid flow rate (L/G RATIO) to the conventional Flue Gas Desulphurization (FGD) system and more Sulphur Dioxide capturing capacity per unit volume of scrubbing liquid. This characterises in the reduction of recirculation system. The Flue Gas Desulphurization (FGD) system also uses unique non plugging low differential pressure spray type scrubber.
MAGO THERMAL FGD is also available in horizontal and vertical versions . MAGO THERMAL HAS SUPPLIED FGD IN TEXTILE, PLYWOOD,LAMINATES & PAPER INDUSTRY.

MAGO ACHIEVED SULPHUR LEVEL even less than 100 PPM which is far lesser than CPCB norms. If this is of INTEREST to you, Kindly share your BOILER Detail’s – enabling us to share ENGINEERING INPUTS including ROI Plans on LIKELY INVESTMENTS for this SYSTEM.

1.      Type of Boiler                                    :    Bi drum / Single drum
2.      BOILER Capacity                             :        TPH
3.      WP                                                       :        KSC
4.      Steam Temp                                       :        Deg C
5.      Mode of firing                                    :    Under Bed  / Over Bed
6.      Fuel used                                            :    Name of fuel  used ?    &   Fuel Quantity with its  rated GCV.
7.      FD Fan details                                   :    Flow (Q), Static Pressure (mmWC), RPM and Motor rating ( kW/P ).
8.      PA fan details same as above         :    Flow (Q), Static Pressure (mmWC), RPM and Motor rating ( kW/P ).
9.      ID fan details same as above          :     Flow (Q), Static Pressure (mmWC), RPM and Motor rating ( kW/P ).
10.  Numbers of Feeders OB / UB          :
11.  Heating Surface of Steam Boiler      :
12.  Scan Copy Of G.A Drawings             :
13.  Scan Copy of Pressure Part Assembly
14.   FUEL and its Analysis   ?
15.  Operation Parameters wrt Temperature, Draught, SPM Emission, Electrical Load, Steam Pressure, Fuel Quantity, Fuel GCV, Steam Fuel Ratio, Oxygen level etc.
and email us on naveen.g@magothermal.com.