Tanjung Jati B Units 3 & 4 660 MW Coal-Fired Project Wet Limestone Flue Gas Desulfurizatio Desulfurization n System
Dewatering System operation & maintenance Wuhan Kaidi Electric Power Environmental Co.,Ltd 1 /61
ABSORBER SYSTEM
Dewatering system process flow Dewatering system equipment Dewatering system startup & shutdown Dewatering system control Dewatering system trouble shooting
2 /61
PROCESS FLOW
Primary Prima ry Dewatering Dewatering - Gypsu Gypsum m Hydroclones Hydroclones 3 /61
PROCESS FLOW
Secondary Secon dary Dewatering Dewatering - Vacuum Belt Filter Filter 4
EQUIPMENT & DATE
Gypsum Hydroclone 60m3/h, Two (2) cyclones per hydroclone (2 spare), PU or Carbon Steel with Rubber Lining
5 /61
EQUIPMENT & DATE
Vacuum Belt Filter 6 /61
EQUIPMENT & DATE
Vacuum belt filter Output Q=10.3t/h, Filter Area 12m2, Carbon Steel and Other Material
7 /61
EQUIPMENT & DATE
Vacuum Receiver Effective Volume 1.5m3,
1.5x1(h)
Vacuum Pump Q=4400m3/h, P=40kPa
Cloth wash tank V=3m3
1.5x1.5(h)
Cloth wash tank pump centrifugal, Q=15m3/h H=60m 8 /61
EQUIPMENT & DATE
Gypsum Gypsu m Hydroclon Hydroclone e Overf Overflow low Tank Tank Effective Volume 8m3,
2x3(h)
Gypsum Gypsu m Hydroclone Hydroclone Over Overflow flow Tank Tank Pump centrifugal, Q=15m3/h
H=35m(slurry head)
Gypsum Hydroclone Overflow Tank Agitator Carbon Steel with rubber Lining Shaft Power=2kw
9 /61
EQUIPMENT & DATE
Waste Water Hydroclone 15m3/h,Cyclones 2+2(Spare)
Chloride purge tank V=35m3,
4x3.5(h)
Chloride purge tank agitator Shaft Power=2.5kw
Chloride Purge Tank Pump centrifugal, Q=15m3/h
H=40m(slurry head) 10 /61
STARTUP & SHUTDOWN
Inspection before system startup 1. The bel beltt convey conveyor or is clea clean, n, with with no no slurry slurry attached to all cylinders. 2. Common syste system m operates operates normally. normally. 3. Gypsu Gypsum m slurry has has proper proper amount of of solids. solids. 4. Vacuu Vacuum m belt conveyor conveyor startup permits permits satisfied satisfied
11 /61
STARTUP & SHUTDOWN
System startup sequence 1: Start up vacuum belt filter wash pump A or B, with a delay time of 30s 2: Start up vacuum belt filter 3: Open vacuum belt filter vacuum pump seal water valve 4: Start up vacuum belt filter vacuum pump, with a delay time of 5s 5: Open vacuum belt filter gypsum slurry feed valve
12 /61
STARTUP & SHUTDOWN
System shutdown sequence 1: Close vacuum belt filter gypsum slurry feed valve, with a delay time of 120s 2: Shut down vacuum belt filter vacuum pump, with a delay time of 120s 3: Shut down vacuum belt filter, with a delay time of 10s 4: Shut down vacuum belt filter wash pump A and B 5: Close vacuum belt filter vacuum pump seal water valve
13 /61
CONTROL
ALARMS:
- Vacuum belt conveyor conveyor belt tracking tracking - Fil Filter ter cloth cloth wash wash wate water r - Va Vacu cuum um pum pump p - Hydroc Hydroclone lone pressu pressure re differenti differential al
14 /61
CONTROL
Inspections:
- Cir Circui cuitt breaker breaker statu statuss - Vibrati Vibration on and tempe temperatures ratures - Vacuum filter belt cleanli cleanliness ness - Slurry overflow in vacuum vacuum filter filter belt slurry distribution box - Leaka Leakage ge of slurry at hydroclone hydrocloness
15 /61
TROUBLE SHOOTING Gypsum dewatering is Poor, with much water content
Slurry Cake Discharge at Vacuum Belt Filter
16 /61
TROUBLE SHOOTING
Filter cloth wash water spray head is blocked.
17 /61
TROUBLE SHOOTING
Gypsum Hydroclone Slurry Leakage
18 /61
TROUBLE SHOOTING
Filterr cloth displa Filte displaceme cement. nt.
19 /61
Tanjung Jati B Units 3 & 4 660 MW Coal-Fired Project Wet Limestone Flue Gas Desulfurizatio Desulfurization n System
Limestone Slurry Prep System operation & maintenance
Wuhan Kaidi Electric Power Environmental Co.,Ltd 1 /61
ABSORBER SYSTEM
Limestone slurry prep system process flow Limestone slurry prep system equipment Limestone slurry prep system startup & shutdown Limestone slurry prep system control Limestone slurry prep system trouble shooting
2 /61
PROCESS FLOW
Wet Ball Mill System 3 /61
PROCESS FLOW
Wet Ball Mill Lubrication System 4
PROCESS FLOW
Absorber Area Sump 5 /61
EQUIPMENT & DATE
Limestone Weigh Weigh Feeder 6 /61
EQUIPMENT & DATE
Wet Ball Mill 7 /61
EQUIPMENT & DATE
8 /61
EQUIPMENT & DATE
Weigh Feeder Q=0
10t/h
L=7m
Wet Ball Mill Q=6.5t/h Carbon Steel and Rubber Lining Shaft power=200kw
9 /61
EQUIPMENT & DATE
Wet Ball Mill Outlet Tank 10 /61
EQUIPMENT & DATE
Mill Hydroclone Q=50m3/h
Mill Outlet Tank Effective Volume 8m3,2.5x2(h)
Mill Outlet Tank Agitator Mill Outlet Tank Pump Q=50m3/h H=30m(slurry head) Shaft power=15kw 11 /61
EQUIPMENT & DATE
Reagent Slurry Storage Tank 4x3.5(h),V=35m3
Reagent Slurry Storage Tank Agitator Shaft power=6kw
Reagent slurry storage tank pump Q=40m3/h H=45m(slurry head) Shaft power=19.5kw
12 /61
EQUIPMENT & DATE
Limestone Slurry Feed Tank 6x5.5(h),V=140m3
Reagent Slurry Feed Tank Agitator Shaft power=3.5kw
Reagent slurry Feed tank pump Q=50m3/h H=35m(slurry head) Shaft power=18.4kw
13 /61
EQUIPMENT & DATE
Limestone Prep Area Sump 443mV=40m3
Limestone Prep Area Sump Agitator Shaft power=3kw
Limestone Prep Area Sump Pump Q=50m3/h H=20m(slurry head) Shaft power=6.7kw
14 /61
STARTUP & SHUTDOWN
Inspection before system startup 1. Lubrication oil system ready 2. Grease level is normal 3. Common system operating normally 4. Limestone silo level > minimum 5. Limestone slurry feed tank level not high
15 /61
STARTUP & SHUTDOWN
Wet Ball Mill Start-up Sequence 1: Start mill lube oil A system and mill lube oil B system 2: Open limestone slurry distributor backward valve A, and close limestone slurry distributor product valve A 3: Open wet ball mill A water flow control valve, and set water flow control set point to 2.5 m3/hour. 4: Start mill outlet tank pump A system or mill outlet tank pump B system 5: Warning light and warning horn will activate automatically prior to start of wet ball mill 6: Start wet ball mill 16 /61
STARTUP & SHUTDOWN
Wet Ball Mill Start-up Sequence 7: Open mill outlet tank water flow control valve, and set flow control dilution water on internal flow set value=9m3/h 8: Start limestone weight feeder 9: Set flow point of mill outlet tank water flow control valve on 1.9 BMNF (Ball mill new feed), and Set flow point of wet ball mill water flow control valve on 0.45 BMNF (Ball mill new feed), and shutdown ball mill flashing light, and shutdown ball mill horn, wait until mill outlet tank pump A or B speed arrives at about 80% of inverter controlled speed range. 17 /61
STARTUP & SHUTDOWN
Wet Ball Mill Start-up Sequence 10: Close limestone slurry distributor backward valve A, and open limestone slurry distributor product valve A 11: Set mill mill outlet outlet tank level level control control on autom automatic atic and set point point wait density value arrives to set density control with mill outlet tank water flow control valve on automation
18 /61
STARTUP & SHUTDOWN
System shutdown sequence 1: Stop limes limestone tone weight weight feeder, feeder, and and ball mill mill process process water controll to set point contro point value value 2.5m 2.5m3/h,a 3/h,and nd dilution dilution water water control to set point value 9m3/h 9m3/h,wait ,wait until density<22wt density<22wt% % low signal is activated (grind out time) 2: Close wet ball mill water flow control valve to 0%, and close mill outlet tank water flow control valve to 0%,wait until mill outlet tank level < 1.0 m (alarm)sig signal nal act activa ivated ted 3: Stop wet ball mill, a delay time of 120 seconds
19 /61
STARTUP & SHUTDOWN
System shutdown sequence 4: Open limestone slurry distributor backward valve A, and close limestone slurry distributor product valve A 5: Stop mill outlet tank pump A system system or mill outlet tank pump B system 6: Stop mill lube oil pump A system and mill lube oil pump B system
20 /61
STARTUP & SHUTDOWN
System emergency shutdown sequence 1: Stop wet ball mill 2: Stop limestone weight feeder, and set grinding water control to internal set point 2.5m3/h,and set dilution water control to internal set point 9m3/h,wait 120 seconds. 3: Close wet ball mill water flow control valve to 0%, and mill outlet tank water flow control valve to 0%, wait 120 seconds. 4: When both above flow control valve position < 1% and mill outlet tank level<1000mm, Open limestone slurry distributor backward valve A, and close limestone slurry distributor product valve A
21 /61
STARTUP & SHUTDOWN
System emergency shutdown sequence 5: If shutdown is expected to last longer than 30 minutes, stop mill outlet tank pump. 6: Shutdown mill lube oil pump A system and mill lube oil pump B system
22 /61
CONTROL
Wet Ball Mill System Control:
- Ball mill outlet tank level - Ball mill outlet tank density density
23 /61
CONTROL
Wet Ball Mill System Alarms:
- Bal Balll mill mill oil syst system em - Bal Balll mill & ball ball mill mill moto motor r - Bal Balll mill mill hydrocl hydroclone one
24 /61
CONTROL
Ball Mill System Checks: - Circ Circuit uit break breaker er status status - Wat Water er / slurry slurry leaka leakage ge - Vibrat Vibration ion & temper temperature ature - Ball mill outlet tank level level / overflow overflow
25 /61
TROUBLE SHOOTING
Steel balls must must be added periodically to maintain maintain ball mill efficiency
26 /61
Tanjung Jati B Units 3 & 4 660 MW Coal-Fired Project Wet Limestone Flue Gas Desulfurizatio Desulfurization n System
FGD Chemical Sample & Analysis
Wuhan Kaidi Electric Power Environmental Co.,Ltd 1 /61
FGD CHEMICAL SAMPLE & ANALYSIS
Limestone sampling and analysis Limestone slurry sampling and analysis Absorber slurry sampling and analysis Gypsum sampling and analysis
2 /61
Limestone Sampling & Analysis
Limestone sampling A compartment for a sampling unit. Each compartment of a sample collection. Sampling point should be from the car wall, and the bottom of not less than 0.3 meters. From the surface of not less than 0.2 meters. Collecting samples of well-mixed into a sample, to conduct sampling. Sampling point as far as possible evenly distributed * It is best to take intermittent samples as limestone is being unloaded from the ship. * Collected samples shall be well-mixed for uniformity of samples to be analyzed.
3 /61
Limestone Sampling & Analysis
Preparation of Limestone samples Acquisition of limestone samples will will be taken to the laboratory, laboratory, the first analysis of particle size, and then be ground into powder, powder, a component of the final.
Analysis Project of Limestone:
- Raw limeston limestonee particle particle size - Parti Particle cle diamet diameter er - Grind Grindabilit ability y Index Index - Mo Mois istu ture re - Rea Reacti ctivit vity y - Ine Inert rt materi material al Particle diameter grin grindabi dability lity inde index x MgCO3 SiO2 Fe2O3 Al2O3
Moisture
inert material
CaCO3
4
Limestone Sampling & Analysis
Common components of limestone Particle diameter < 20mm grindab gri ndabili ility ty ind index ex < 12 5% Moisture <
Inert material CaCO3
no larger than 5% 90%~95%
MgCO3
1%~3%
SiO2
1%~2%
Fe2O3
1%~2%
Al2O3
1%~3%
5
Limestone Sampling & Analysis
Limestone analysis frequency
Do not replace the limestone mine in the circumstances, its composition will not be much change, the composition analysis does not require a high frequency. But the limestone particle size and moisture content by artificial interference and weather significantly, the need to strengthen analysis.
* collect samples when each ship is unloaded. * Based on consistency of limestone analysis between shipments, analysis of limestone can be less frequent
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