Acid Gas Scrubber for Multi-Pollutant Reduction Emission Control and Measurement Workshop March 24-25, 2010 Nicholas Confuorto Belco Technologies Corporation Belco Technologies Corporation Founded in 1968, was part of Foster Wheeler until 1989 Now subsidiary of DuPont Located in Parsippany, New Jersey Employing about 65 people Worldwide Supplier of Technologies for Controls of Particulate, SOX and NOX emissions Specializing in reduction of Oil Refinery Emissions More systems installed and operating than ALL other competitors “COMBINED” Offering a wide range of solutions to better serve our customers Certified ISO 9001-2000 Reducing Particulate, SOx and NOx in a single vessel The old long train Approach To Pollution Controls (No Control of Particulate, SOx or NOx during Boiler Bypass) ESP # FCC Boiler ESP # (Particulate) (Particulate) ReHeat SCR DeSOx (NOX)) (NOX (SO2)) (SO2 Stack Reducing Particulate, SOx and NOx in a single vessel The old long train Approach To Pollution Controls (No Control of Particulate, SOx or NOx during Boiler Bypass) ESP # FCC Boiler ESP # (Particulate) (Particulate) ReHeat SCR DeSOx (NOX)) (NOX (SO2)) (SO2 Stack THE OLD APPROACH IS: •COSTLY •USES TOO MUCH PRECIOUS REFINERY SPACE •IS SUBJECT TO TOO MUCH MAINTENANCE AND POSSIBLE DOWN TIME •DOES NOT PROVIDE POLLUTION REDUCTION DURING BOILER BYPASS Reducing Particulate, SOx and NOx in a single vessel The old long train Approach To Pollution Controls (No Control of Particulate, SOx or NOx during Boiler Bypass) ESP # FCC Boiler ESP # ReHeat (Particulate) (Particulate) SCR DeSOx (NOX)) (NOX (SO2)) (SO2 Stack The Multi-Pollutant Approach To Pollution Controls (Pollutants Controlled even during Boiler Bypass) FCC Boiler BELCO’s EDV System Particulate, SOx and NOx combined •Less Space Required •Lower Cost •Higher Efficiency •Highest Flexibility •Higher Reliability •Full control even during boiler bypass •Can change with your requirement EDV® Wet Scrubbing System Reducing Particulate, SO2, SO3 and NOx in a single vessel EDV® Wet Scrubbing Advantages No Mist Formation • No Demister • No Mist Fallout Plot Area • Small • Flexible Highly Reliable Highly Efficient Can provide Combined Particulate, SO2, NOx and SO3 Control Non Plugging • Nozzles, Vessel & Component Design • Handles High Dust Loads Even FCCU Upsets • Highly Reliable Modular & Integral • Single System for all pollutants • Multi-Staged Collection EDV® Wet Scrubbing Design Step – Flue Gas is quenched and saturated in the Quench Section Initial reduction of particulate, SO2 and SO3 is achieved in this step The EDVđ Quench Section ã Designed to fully saturate gas • Unique design minimizes Wet/Dry interface Quench Section • Can be designed to allow the full regenerator temperatures EDV® Wet Scrubbing Design Step – Reduction of SO2 and Primary Particulate Control is achieved in the Absorber Section 10 LoTOxTM data -Medical College of Ohio Performance of LoTOx System at MCO December 6, 2001 Outlet NOx Setpoint = PPM Changed to 10 PPM 40000 70 35000 30000 Inlet NOx 50 25000 40 30 Flue Gas Flow 20 Flue Gas Temp = 179 - 234 F Scrubber Temp = 75 - 100 F Inlet SOx = 74 - 178 ppm Inlet CO = 150 - 300 ppm 10 Outlet NOx 20000 15000 10000 5000 0 0: 00 0: :00 52 1: :00 44 2: :00 36 3: :00 28 4: :00 20 5: :00 12 6: :00 04 6: :00 56 8: :00 45 9: :15 10 7:1 :2 11 9:1 :2 12 1:1 :1 13 3:1 :0 13 5:1 :5 14 7:1 :4 15 9:1 :4 16 1:1 :3 17 3:1 :2 18 5:1 :1 19 7:1 :0 20 9:1 :0 20 1:1 :5 21 3:1 :4 22 5:1 :3 23 7:1 :2 9: 15 NOx PPM 60 Flue Gas Flow, ACFM 80 Time 33 LoTOxTM data – Refinery FCCU 34 Demonstrated Performance 80 70 60 A verage R eactor Tem perature = 153 F S x in = 211 ppm O Flow R ate = 224 scfm A verage N x R oval = 87% O em N x (p m O p 50 40 30 20 10 ppm NOx set point 10 22:55:12 23:02:24 23:09:36 23:16:48 23:24:00 23:31:12 23:38:24 Tim e NO -IN x NO -O x UT 35 EDV® Wet Scrubbing Simplified PFD 36 CLEAN GAS OUT EDV® Caustic System PFD EDV® STACK Model 1000 EDV® Model 5000 Model 6000 EDV DROPLET SEPARATORS MAKEUP WATER FC (This loop is for EDV® 5000, 6000 and 6600 models only) (for EDV® 5000 and 6000 models only) EDV® FILTERING MODULES (for EDV pHC 5000, 6000 and 6600 models only) DIRTY FLUE GAS FROM FCC EDV ABSORBER FC CAUSTIC EDV QUENCH OVERFLOW DRAINS FC pHC LC FC EMERGENCY OVERFLOW SLIPSTREAM TO PURGE TREATMENT UNIT 37 CLEAN GAS OUT EDV® Scrubbing System PFD EDV® STACK EDV® DROPLET SEPARATORS MAKEUP WATER FC (This loop is for EDV® 5000, 6000 and 6600 models only) (for EDV® 5000 and 6000 models only) EDV® FILTERING MODULES (for EDV pHC 5000, 6000 and 6600 models only) EDV ABSORBER CAUSTIC DIRTY FLUE GAS FROM FCC EDV QUENCH LoTOxTM Injection 02 FC pHC 03 OZONE GENERATOR FC LC FC SLIPSTREAM TO PURGE TREATMENT UNIT 38 EDV® scrubbing with LoTOxTM Process Ozone Injection Grid in Quench Section 39 Liquid Discharge elimination using the BELCO LABSORBTM System 40 LABSORBTM Regenerative SO2 Scrubbing System Scrubber Regeneration Plant 41 LABSORBTM Regenerative Wet Scrubbing Sodium Phosphate Solution (“buffer”) used to absorb SO2 Buffer is Regenerated and sent back to the absorber to scrub SO2 Only product from regeneration is a concentrated SO2 stream that is then converted to elemental sulfur or sulfuric acid Reduces load on Waste Water Treatment Plant Reduced Reagent Cost (Caustic) Enhanced Recovery (Sulfur) 42 LABSORBTM Regenerative Wet Scrubbing Basics - Regeneration Side Buffer Regenerated using Evaporation with low pressure steam Sulfates and heat stable salts formed from SO3 and oxidation of SO2 are removed as a solid by a patented process Less than 3% buffer loss LABSORBTM Regenerative Wet Scrubbing Installed years ago as SRU tail gas treater at a Refinery in Europe Operating on a 40,000 bpsd FCCU in Italy since June 2003 Operating on a 60,000 bpsd FCCU in the USA since October 2004 LABSORBTM Absorber and Full Pre-scrubber GAS OUT Polishing-Scrubber Built inside stack GAS IN From FCCU Lean Buffer From Regeneration Plant DROPLET SEPARATORS FC PRE-SCRUBBER (EDV® 6000) 1 1 FILTERING MODULES 2 Make-Up MakeWater 2 DROPLET SEPARATORS 3 LABSORBTM Regeneration Plant LC FC FC Pre-Scrubber PrePurge to Clarifier 3 Rich Buffer To Regeneration Plant SO2 to Sulfur Plant 45 LABSORBTM Regeneration Plant (simplified) “SINGLE EFFECT” EVAPORATION CONDENSER RICH BUFFER FROM SCRUBBER Vapor Liquid Separator 35 PSIG STEAM Recovered SO2 to SRU or Acid Plant CW STRIPPER EVAPORATOR 35 PSIG Condensat e Tank STEAM CONDENSATE COOLER cw BUFFER TO SULFATE REMOVAL LEAN BUFFER BACK TO SCRUBBER STRIPPER CONDENSATE TO SULFATE REMOVAL MIXING TANK 50%NaOH 85% H3PO4 46 QUESTIONS? 47 ... EDV 5000 and 6000 models) 17 Multiple Modules in Each Scrubber Efficient and Reliable Fine Particulate Control Internal Drain Pipe Scrubber Exterior Scrubber Exterior Scrubber Interior Scrubber. .. Worldwide Supplier of Technologies for Controls of Particulate, SOX and NOX emissions Specializing in reduction of Oil Refinery Emissions More systems installed and operating than ALL other competitors... FC (This loop is for EDV® 5000, 6000 and 6600 models only) (for EDV® 5000 and 6000 models only) EDV® FILTERING MODULES (for EDV pHC 5000, 6000 and 6600 models only) DIRTY FLUE GAS FROM FCC EDV