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2/15/2021 1
Confidential – for internal use only
Application:

Flue Gas Desulfurization

in Power Plants
by Martin W. Goebel
Sales Director Analytics

Confidential – for internal use only

The problem: emission of sulfur dioxide SO2

Sources of SO2:
■ Coal-fired power plants
■ Oil-fired power plants
■ Waste incinerators

Quelle: jelwolf /
Comparison of emissions for various fossil fuels: Fotolia.com

Pollutant Hard coal Brown coal Fuel oil Gas

CO2 (g/GJ) 94,600 101,000 77,400 56,100
SO2 (g/GJ) 765 1,361 1,350 0.68
NOx (g/GJ) 292 183 195 93.3
CO (g/GJ) 89.1 89.1 15.7 14.5

15.02.2021 3
Confidential – for internal use only
 Serious effects of SO2 on human health and environment

Sulfuric acid is formed by combination

of SO2 and water in the air =
acid rain!

Negativ effects of acid rain:

■ Respiratory problems
■ Forest decline
■ Acidification of lakes and Oceans
■ Damaging of buildings

→ SO2 must be removed!

→ flue gas desulfurization FGD

15.02.2021 4
Confidential – for internal use only
Global sulfur dioxide emissions

High quantities of SO2 emitted

worldwide (peak in 1980):

■ Reduction of coal/oil as fuel for

power plants (EU/US)
■ SO2 amount decreases due to
environmental directives (low sulfur
fuels and FGD)
■ Increase of SO2 emissions in Asia,
Africa and South America to cover
high growing demand for cheap
electrical energy

15.02.2021 5
Confidential – for internal use only
Flue gas desulfurization (FGD)

Removal of SO2 via precipitation as gypsum = CaSO4

■ Addition of oxygen
■ Limestone (CaCO3)
■ burned lime (CaO)
■ milk of lime (Ca(OH)2)
Gypsum is reused for building
materials e.g. gypsum plaster board
2 SO2 + 2 Ca(OH)2 → 2 CaSO3 + 2 H2O

2 CaSO3 + O2 + 4 H2O → 2 [CaSO4∙2 H2O]

2 SO2 + 2 Ca(OH)2 + O2 + 2 H2O→ 2 [CaSO4∙2 H2O]

15.02.2021 6
Confidential – for internal use only
Industrial processes for FGD

■ Venturi scrubber
■ Packed-bed scrubber
■ Spray tower

Venturi scrubber/wikipedia.org Packed-bed scrubber/wikiwand.com

15.02.2021 7
Confidential – for internal use only
Measuring point 1: pre-scrubber

Schematic of exhaust gas treatment in a coal fired power plant

Main scrubber
■ Cooling hot flue gas by injecting for SO2 removal NOx-removal

milk of lime Electro-static filter

Bag filter
■ pH is typically between 1-2 (pH Off-gas
from boiler
must not rise above 2)
■ Precipitation of hydro-chloric acid
HCl, hydro-fluoric acid HF and
heavy metals (e.g. mercury Hg)
■ Corrosive conditions
■ No SO2 binding at this stage (!)
■ Online pH measurement (!)

Pre-scrubber

Off gas stack

15.02.2021 8
Confidential – for internal use only
Measuring point 2: main scrubber

■ Increasing pH by addition of lime

■ Online-monitoring pH for correct lime milk
addition (optimum conditions: pH 5.6-6.0).
Overdosage of lime must be avoided. If pH
too high, gypsum will contain excess milk of
lime. If pH too low, removal rate of SO2
will be reduced.
■ Point of installation: in circulation line of
Ca(OH)2/gypsum sludge
■ Heavy incrustations
■ High solids content (2-15 %)
■ Deposit formation
■ Abrasive and corrosive sludge

15.02.2021 9
Confidential – for internal use only
Measuring point 3: neutralization of excess Ca(OH)2

■ Water must be neutralized after

precipitation/thickening of the gypsum
■ Addition of sulphuric acid, binding the
excess of lime (Ca(OH)2)
■ Online pH measurement (!)
■ High solids content (2-15 %)
■ Deposit formation/incrustation
■ Abrasive/corrosive sludge

Abrasive damage of
glass membrane

15.02.2021 10
Confidential – for internal use only
Knick equipment in use: Protos-Unical-Ceramat

Probe Controller
■ Solution Unical 9000(X)
Analyzer
■ Fully-automated pH measurement Protos
system Unical9000 3400(X)
■ pH sensor: SE554 or SE571
Service switch
■ Fitting: Ceramat WA150

Sensor lock gate

SE571 (Knick) SE554 (Knick)

15.02.2021 11
Confidential – for internal use only
For the toughest demands: Ceramat like Ceramic

Advantages:

■Solid ceramic body and ceramic sealing

surface
■Polished ceramic inner housing
prevents incrustations
■Gaskets never in contact with process
fluid
■PVDF or PEEK housing protects against
harsh process media
■Enhanced lifetime of the sealings due
to permanent rinsing
■cleaning with acid or base
■No shadowing by the electrode tip
■Excellent rinsing effect due to circular
flow pattern

in cleaning / in operation
Confidential – for internal use only
FGD in a coal fired power plant in Germany

Water processing (neutralization) after gas scrubbing using Installation of Ceramat-fitting into main pipeline in
Protos, Unical and Ceramat neutralization process

Confidential – for internal use only

FGD in a coal fired power plant in Germany

Heavy incrustations on the Ceramat- fitting Installation of Ceramat-fitting directly into SO2-absorber tank

Confidential – for internal use only

Manual Retractable Fitting WA131M in FGD

pH & ORP Measurements on FGD

Scrubbers
Duke Energy – Gibson Station
Indiana, USA

Stratos Evo
SE 555 & SE 565 (pH & ORP)
Retractable Holders
SensoGate WA 131M

ROI:
Previous sensor calibration and
replacement took up to 4 hours.
Knick System takes 15 minutes!
No process interruption!

WA 131 M
Confidential – for internal use only
FGD in coal fired power plant in Indonesia (1000 MW)

Knick products in use, 2 sets:

Protos 3400 C / FIU 3400-141-2

Uniclean 900-NCF0A2CN-000
WA 153-N0KBB31105BD10-00
SE 571X/2-NMSN

Protos and Uniclean are

pre-installed in an
electrical cabinet in factory
in Japan and shipped to
Indonesia resulting in easy
and quick installation at
site.

Confidential – for internal use only

Coal fired power plants in planning stage (in MW)

Confidential – for internal use only

The future of energy generation technology ?

Confidential – for internal use only

What is our competition doing? E+H:

CDC90 from E+H:

Pros:
■ 2 channel option
■ Profinet+Ethernet communication

Cons:
■ Only in non ex
■ No Ceramat

Confidential – for internal use only

What is our competition doing? METTLER:

Product EasyClean 100 EasyClean 150 EasyClean 200e EasyClean 350e EasyClean 400(X)

Product image

Ex-area approval
Sensor flushing with water/air / / / / /
Sensor cleaning with chemicals - -
Sensor calibration with buffers - -
Operation modes Manual, automatic Manual, automatic Manual, automatic Manual, automatic Manual, automatic
X100e, M300, X100e, M300, X100e, M300,
Transmitter Not known M700(X) = Protos (!)
M700, Trb8300 M700, Trb8300 M700, Trb8300
Analog / digital interfaces - -
Digital communication - - - - PROFIBUS PA / FF
Protection rating IP65 IP 65 IP65 IP65
Made by Knick,
Not produced anymore
REMARK cooperation stopped in
since October 2014
2020
Confidential – for internal use only
What is our competition doing? EXNER:

Product EXmatic 450 EXmatic 460

Pros:
■ Simple and low cost system
Product image
Cons:
■ IP 54 protection, no ex
Ex-area approval - - ■ Only for cleaning, no calibration
Sensor flushing with water/air / / ■ No transmitter/sensor available from
Sensor cleaning with chemicals Exner
Sensor calibration with buffers ■ Limited communication
Operation modes Manual Manual, automatic
■ No Ceramat fitting
Transmitter None None
Analog / digital interfaces -
Digital communication - -
Protection rating IP54 IP54
REMARK - -

Confidential – for internal use only

Marketing material

■ Application report ■ Reference list of 41

installations

In preparation:

Knick brochure
„Applications in power
plants“

15.02.2021 22
Confidential – for internal use only
Thank you for your attention!

Knick
Elektronische Messgeräte
GmbH & Co. KG

www.knick.com

Now is time for your questions! Please

use the Chat-Function!

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Do not miss our next seminars!

■Feb 23: P51000 in Combination with MXX00HS for Energy Measurement

(Interface)

■March 2: Profinet for Protos (Analytics)

■March 16: pH and COND Measurement in Pigment Industry (Analytics)

Confidential – for internal use only