Tanjung Jati B Training

FGD OVERVIEW
 OVERVIEW
FGD SYSTEM

Tanjung Jati B Training

PT Central Java Power
Tanjung Jati B Units 1 & 2
Flue Gas Desulfurization (FGD) System

Absorber Area Dewatering Reagent Preparation Limestone Jetty

Area Area And Conveyor

Tanjung Jati B Training

 FGD Overview
Isometric View

Absorber Module
By-Pass Flue Precipitator
(Casing B)
Absorber
Module

Induced
Draft Fan
Precipitator
(Casing A)

Tanjung Jati B Training

FGD Overview
Isometric View

UNIT-2
UNIT-1
ID FANS
ABSORBER
RECIRCULATION
PUMPS
Tanjung Jati B Training
FGD Overview
FGD System

The FGD System is comprised the following

systems…

● Limestone Handling & Storage

● Reagent Preparation
● Absorbers (SO2 Removal)
● Dewatering
● Seawater Make-up

Tanjung Jati B Training

FGD Overview
FGD System

The FGD System is comprised the following

systems…

● Limestone Handling & Storage

● Reagent Preparation
● Absorbers (SO2 Removal)
● Dewatering
● Seawater Make-up

Tanjung Jati B Training

FGD Overview
Limestone Handling

The system serves to transport raw limestone

from the limestone jetty to the limestone
storage silos. One silo can be filled at a time,
not both at the same time!

The operation of the system is handled by

a Programmable Logic Controller (PLC) and
is completely independent from other
control systems.

Tanjung Jati B Training

FGD Overview
Limestone Handling

This system consists of six (6) basic

components…

● Stockout Conveyor
● Storage Pile
● Bucket Elevator
● Reversing Conveyor
● Limestone Silos & Dust Collectors
● Limestone Handling PLC

Tanjung Jati B Training

FGD Overview
Limestone Handling

Reversing NOTE: Each Silo has a Dust Collector

Conveyor located on top
Bucket
Elevator

Unloading
Vibrating
Feeder
Magnetic
Separator

Reclaim Stockout Conveyor

Limestone Limestone Vibrating Limestone
Silo A Silo B Feeder Storage Pile

Tanjung Jati B Training

FGD Overview
Limestone Handling

The operation of the Limestone Handling

system is handled by a Programmable Logic
Controller (PLC) and is completely independent
from other control systems.

Tanjung Jati B Training

FGD Overview
Limestone Handling

PANEL IS
LOCATED AT
GROUND LEVEL
NEXT TO THE
BUCKET
ELEVATOR

Front View of Panel

Tanjung Jati B Training
FGD Overview
FGD System

The FGD System is comprised the following

systems…

● Limestone Handling & Storage

● Reagent Preparation
● Absorbers (SO2 Removal)
● Dewatering
● Seawater Make-up

Tanjung Jati B Training

FGD Overview
Reagent Preparation

The function of Reagent Preparation is to

process raw limestone stored in the Limestone
silos into a limestone “slurry” which is ultimately
stored in the Limestone Slurry Storage Tank.

The “fresh” limestone slurry, produced by the

Vertical Ball Mills, is used to replace “Gypsum”
slurry which exits or leaves the Absorber Modules
during operation.

Tanjung Jati B Training

FGD Overview
Reagent Preparation

This system consists of six (6) basic

components…

● The Vibrating “Bin Activator”

● Limestone Feeder
● Limestone Pre-Crusher
● Vertical Ball Mills
● Hydroclones & Mill Outlet Sump
● Limestone Slurry Storage Tank

Tanjung Jati B Training

FGD Overview
Reagent Preparation
Limestone
Silo

Bin Activator
Mill
Hydroclone

Limestone
Feeder Limestone
Pre-Crusher Limestone Slurry
Mill Storage Tank
Recirculation
Sump
Seawater

30%
Vertical SOLIDS
Ball Mill

Mill Recycle Mill Outlet

Pump Sump
Tanjung Jati B Training
FGD Overview
Reagent Preparation

The “fresh” slurry produced by the Reagent

Preparation System, by design, will have a
solids content of 30%.

Control of the Reagent Preparation System

is from the main control room. The system is
operated most efficiently as a batch process
with a constant design feed rate of limestone
to the vertical ball mills.

Tanjung Jati B Training

FGD Overview
FGD System

The FGD System is comprised the following

systems…

● Limestone Handling & Storage

● Reagent Preparation
● Absorbers (SO2 Removal)
● Dewatering
● Seawater Make-up

Tanjung Jati B Training

FGD Overview
Absorber Area

The Absorber Module converts or “absorbs”

the Sulfur Dioxide (SO2) in the flue gas by
chemical reactions with the Limestone
Slurry.

Calcium Carbonate (CaCO3) in the Limestone

Slurry is converted to Calcium Sulfite (CaSO3).

Tanjung Jati B Training

FGD Overview
Absorber Area

Clean Gas

Flue Gas

ABSORBER MODULE

Tanjung Jati B Training

FGD Overview
Absorber Area

Oxidation Air is introduced in the Reaction

Tank of the Absorber Module where Calcium
Sulfite (CaSO3) is converted to Calcium
Sulfate (CaSO4).

Tanjung Jati B Training

FGD Overview
Absorber Area

The conversion of Calcium Sulfite (CaSO3) to

Calcium Sulfate (CaSO4) serves to minimize
“scaling” or formation of solids on internal
components within the Absorber Module.

Tanjung Jati B Training

FGD Overview
Absorber Area

Flue Gas

Reaction
Tank
Oxidation Air
Headers

Tanjung Jati B Training

FGD Overview
Absorber Area
● Gas to Sorbent (Limestone Slurry) Reaction

CaCO3 + SO2 + H2O → CaSO3 • 1/2H2O + CO2

Calcium Carbonate Flue Calcium Sulfite
(In Limestone) Gas

● Forced Oxidation Reaction

CaSO3 • 1/2H2O + O2 + H2O → CaSO4 • 2H2O

Calcium Sulfate

(There are many other intermediate reactions)

Tanjung Jati B Training

FGD Overview
Absorber Area

MOTOR

BLOWER

TWO OF THREE BLOWERS IN HIBON SHOP

Tanjung Jati B Training

FGD Operations
Absorber Area

OXIDATION AIR BLOWERS

NEXT TO THE DEWATERING BUILDING
Tanjung Jati B Training
FGD Overview
Absorber Area

Each Absorber Module is equipped with four (4)

Absorber Recirculation Pumps.

The pumps recirculate slurry from the Reaction Tank

to the two (2) levels of spray headers.

Tanjung Jati B Training

FGD Overview
Absorber Area

Limestone Slurry
Recirculation
Level-2
Design Basis: Level-1
(Bengalon Coal @ 1%
Sulfur @ ECR)

Recirculation
• 3 Pumps In-Service Pumps (x4)
• 1 Pump Standby

Tanjung Jati B Training

FGD Overview
Absorber Area

The Slurry from the spray headers collects on the

Absorber Trays where Calcium Carbonate (CaCO3)
from the Limestone Slurry is converted to Calcium
Sulfite (CaSO3).

Tanjung Jati B Training

FGD Overview
Absorber Area
Absorption Zone
(SO2 Capture)

Flue Gas

TRAYS

Tanjung Jati B Training

FGD Overview
Absorber Area

The Absorber Module also has four (4) Reaction

Tank side-entry Agitators.

Their function is to maintain solids in suspension.

Tanjung Jati B Training

FGD Overview
Absorber Area

Reaction Tank

Agitators (x4)
Tanjung Jati B Training
FGD Overview
Absorber Area

In order to prevent moisture leaving the Absorber

Module, which is known as “moisture carryover”,
the Module is equipped with two (2) sets of Mist
Eliminators.

Tanjung Jati B Training

FGD Overview
Absorber Area
Mist Eliminators
(Moisture Separators)
Minimizes the amount of slurry
droplets (moisture) leaving the
absorber module

Tanjung Jati B Training

FGD Overview
Absorber Area

To keep the Mist Eliminators relatively clean

of slurry deposits, a system of Wash Water
Nozzles are used.

Tanjung Jati B Training

FGD Overview
Absorber Area

Mist Eliminator Wash

Water Spray Nozzles
• Function is to minimize the buildup
of deposits on the blades. Water is
sprayed on a periodic (timed) basis.
• Water source is seawater!
2nd Stage Underflow Sprays

1st Stage Overflow Sprays

1st Stage Underflow Sprays

Tanjung Jati B Training

FGD Overview
Absorber Area

Each Absorber utilizes two (2) 100% capacity

Gypsum Slurry Pumps. The basic function of
the pumps is to control Reaction Tank Density.

Tanjung Jati B Training

FGD Overview Flow Streams
Absorber Area
Flue Gas To Stack

From Absorber
Mist Eliminator Bypass Flue
Wash Water LEVEL-2

LEVEL-1

From LS Slurry Storage Tank

(SO2 & pH Control)
From Hydroclone O/U Sump
Flue Gas
From ID Fans From Process Water Tank
(Level Control)

Oxidation Air To Dewatering Hydroclones

Absorber Recirculation Gypsum Slurry

Pump (x4) Pump (x2)
(Density Control)

Tanjung Jati B Training

FGD Overview
FGD System

The FGD System is comprised the following

systems…

● Limestone Handling & Storage

● Reagent Preparation
● Absorbers (SO2 Removal)
● Dewatering
● Seawater Make-up

Tanjung Jati B Training

FGD Overview
Dewatering Area

The Dewatering System serves to remove

water from the Gypsum Slurry produced in
the Absorber Module during unit operation.

The Final Product, which is referred to as

“gypsum” cake, by design will have a
solids content of 80% (20% water)

Tanjung Jati B Training

FGD Overview
Dewatering Area

This system consists of five (5) basic

components…

● Gypsum Slurry Feed Pumps & Hydroclones

● Hydroclone Overflow/Underflow Sump
● Filter Feed Tank
● Vacuum Filter Feed Pumps
● Vacuum Filters

Tanjung Jati B Training

FGD Overview
Dewatering Area

The Dewatering System is broken down

into two processes; Primary and Secondary.

The Hydroclones are the first or Primary

step, while the Vacuum Filters serve as the
final or Secondary part of the process.

Tanjung Jati B Training

FGD Overview
Dewatering Area
Absorber
Module

Vacuum
Filter
Vacuum Filter
Vacuum Receiver

Blowdown
Skid
Gypsum Hydroclone
Slurry Pump Chloride Seawater

Vacuum
Filter Feed
Pump

Hydroclone Filter Feed Process

Overflow/Underflow Tank Water Tank
Sump
FGD Blowdown To Onsite
Sump Landfill
Tanjung Jati B Training
FGD Overview
Dewatering Area

Primary Process:

The Hydroclones function to increase

the solids content in the Gypsum Slurry
from 15% to 45% prior to being stored in
the Vacuum Filter Feed Tank.

Tanjung Jati B Training

FGD Overview
Dewatering Area
Absorber
Module
15% Solids
Vacuum
Filter
Vacuum Filter
Vacuum Receiver

Blowdown
Skid
15% Gypsum Hydroclone
Slurry Pump Seawater
45%
Chloride

Vacuum
Filter Feed
Pump

Hydroclone Filter Feed Process

Overflow/Underflow Tank Water Tank
Sump
FGD Blowdown To Onsite
Sump Landfill
Tanjung Jati B Training
FGD Overview
Dewatering Area

Secondary Process:

The Vacuum Filters process slurry stored

in the Vacuum Filter Feed Tank and process
it to produce a “gypsum” cake containing
80% solids (20% water).

Tanjung Jati B Training

FGD Overview
Dewatering Area
Absorber
Module
15% Solids
Vacuum
Filter
Vacuum Filter
Vacuum Receiver

Blowdown
Skid
15% Gypsum Hydroclone
Slurry Pump Seawater
45%

45%
Chloride

Vacuum 80%
Filter Feed <1%
Pump

Hydroclone Filter Feed Process

Overflow/Underflow Tank Water Tank
Sump
FGD Blowdown To Onsite
Sump Landfill
Tanjung Jati B Training
FGD Overview
Dewatering Area

The “gypsum” cake is discharged into the

Dewatering Building bunker.

A Front End Loader and Articulating

Dump Truck are used to remove and
transport the “gypsum” cake to the
Landfill.

Tanjung Jati B Training

FGD Overview
Dewatering Area
PERCENT SOLIDS
Absorber
Module

Vacuum
3.5% Filter
15%
Vacuum Filter
Vacuum Receiver

Blowdown
Gypsum Skid
Slurry Pump Hydroclone
15% Seawater
45% 1.7%

45%
Chloride

Vacuum 80% <1%

Filter Feed
Pump

Hydroclone Filter Feed Process

Overflow/Underflow Tank Water Tank
Sump
FGD Blowdown To Onsite
Sump Landfill
Tanjung Jati B Training
FGD Overview
FGD System

The FGD System is comprised the following

systems…

● Limestone Handling & Storage

● Reagent Preparation
● Absorbers (SO2 Removal)
● Dewatering
● Seawater Make-up

Tanjung Jati B Training

FGD Overview
Seawater Make-up

There are two (2) 100% capacity, vertical-shaft,

4-stage Seawater Pumps located at the cooling
water sump.

Each pump is capable of delivering 288 m3/hr.

Tanjung Jati B Training

FGD Overview
Seawater Make-up

The seawater is used for the following…

Vertical Ball Mill Grinding

Ball Mill System Flush
Mist Eliminator Wash Water
Process Water Tank Make-up Water
Limestone Slurry Loop Flush

See P&ID Drawing 518523E

Tanjung Jati B Training

 FGD Overview
Seawater Make-up
BURIED
SEWATER PIPING

4-STAGE SEAWATER PUMP

COOLING
WATER SUMP

LIMESTONE
SILOS

DEWATERING
BUILDING

NOTE: SEAWATER IS NOT

REQUIRED IN THE
ABSORBER AREA

SEWATER PIPING
ON PIPE RACK “A”

Tanjung Jati B Training

 PLANT
FGD Overview NORTH

System Plan View

1 2 PIPE
RACK “A”
1 UNIT-1 ABSORBER
2 UNIT-1 RECIRCULATION PUMPS
3 UNIT-2 ABSORBER 5
4 UNIT-2 RECIRCULATION PUMPS
5 FILTER FEED TANK 6 8
6 ME WASH WATER TANK 14
7
7 PROCESS WATER TANK
8 VACUUM FILTERS
9 OXIDATION AIR BLOWERS
9
10 LIMESTONE SLURRY TANK
11 LIMESTONE SILO “A”
12 LIMESTONE SILO “B”
13 LS BUCKET ELEVATOR & RAMP 3 4 PIPE
14 STACK RACK “B”
BURIED SEAWATER TERMINAL POINT
11
YARD PIPING
10 13

12

Tanjung Jati B Training

 OVERVIEW
FGD SYSTEM
(END)

Tanjung Jati B Training