com
Comprehensive
Environmental
Excellence
Air Quality Control Systems
for Thermal Power Plants
Joint Venture Partners – The Power of Two
Air Quality Control Systems
L&T–Sargent & Lundy Limited (L&T-S&L) provides engineering and consulting services to electric power businesses across the globe. L&T-S&L and Sargent & Lundy (S&L) offer a wide range of Air Quality Control System (AQCS) Services to reduce PM, SOx, NOx and
A joint venture of Larsen & Toubro Limited, India and Sargent & Lundy L.L.C, USA, the Company has been in operation since 1995. Hg emissions in coal-based power plants across the world.
It combines deep domain expertise, internationally-aligned systems and processes, as well as unique 3D modeling techniques to
converge technical consultancy with high-end solutions and delivery.
Over the past two decades, S&L has S&L's Environmental Retrofit Experience Summary
enabled many plant owners to develop Technology Units MW
strategic compliance plans to address
Selective Catalytic Reduction >58 >30,800
myriad regulations at federal and state
levels. These strategic planning activities Selective Non-Catalytic Reduction >30 >11,500
have led to an industry-leading role for Dry Flue Gas Desulphurisation >35 >16,600
S&L in the engineering, design,
Wet Flue Gas Desulphurisation >43 >21,400
construction, and deployment of emission
control technologies across the U.S. utility Flue Gas Desulphurisation System Upgrades >32 >27,600
industry. Mercury Control – Activated Carbon >136 >61,200
S&L's expertise and knowledge-base Mercury Control – Co-benefit analysis >70 >31,600
enables L&T-S&L to provide comprehensive Dry Sorbent Injection – SO2 >28 >15,100
and proven engineering services to meet Dry Sorbent Injection – SO3 / HCl >41 >19,700
the emerging needs of stringent
environmental emission control norms. Fabric Filter >64 >26,200
Electrostatic Precipitator >48 >23,400
Larsen & Toubro Limited, India (L&T) is a Sargent & Lundy L.L.C, USA (S&L), with over 125 years of
major technology, engineering, experience in providing engineering services exclusively
construction, manufacturing and financial focused on power, is acknowledged as a premier force
services conglomerate, with global worldwide. S&L has extensive and credible consulting
operations. L&T addresses critical needs experience for gas-based open and combined-cycle projects,
in key sectors - Hydrocarbon, Power, coal-based and environment projects, renewable energy and
Infrastructure, Process Industries and nuclear projects. S&L has been continuously ranked among
Defence. The Company’s products are the top five US-based firms in Power by Engineering News
exported to over 30 countries worldwide. Record (ENR).
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Services offered for AQCS AQCS Technology
Comprehensive experience and technical acumen enable the environmental experts of L&T-S&L and S&L to help plant owners to
comply with regulatory norms, while minimising the risk and capital expenditure. The following sections briefly describe the key
technologies that would suit the specific requirements of your plant.
BLEED SOLIDS TO
WATER ABSORBER STREAM SECONDARY
DEWATERING
AIR M
DAY BIN
VACUUM BELT FILTER
FORCED AIR
COMPRESSOR
OVERFLOW ROTARY DRUM FILTER
BALL MILL AERATION OXIDIZES OR
CaSO3 TO
CRYSTALLINE CaSO4
FILTRATE
LIMESTONE IS WET-GROUND GYPSUM
TO PRODUCE REAGENT SLURRY
• Can accept a wide variety of fuel sulphur levels • Highly efficient at removing SO2 and other acid gases • Can reduce
mercury emissions • Can produce a saleable byproduct (gypsum)
BYPASS DUCT
GGH
AERATION FANS
ABSORBER
TO OTHER FGD UNITS EFFLUENT
BOOSTER FAN
ID FANS
INLET ISOLATION DAMPER
CONCEPTUAL DESIGN AND IMPACT ASSESSMENT EXECUTION PHASE
• Design Basis • Byproduct Disposal Study • Project Management
• Technology Selection • Economiser Bypass Study • System Design ABSORBER PUMPS
2 3
AQCS Technology AQCS Technology
HEAD
TANK NOX CONTROL-SELECTIVE CATALYTIC AND NON-CATALYTIC REDUCTION SYSTEMS
OPTIONAL FLY-ASH LIME SLURRY
FLUE GAS FROM PRE-COLLECTION DRIED AND
AIR PRE-HEATER M PARTIAL SO2
REACTION FURTHER SO2
REACTION ON
ESP BAGHOUSE CAKE
DESULPHURIZED
BAGHOUSE FLUE GAS TO
OR ESP
ID FAN
CHIMNEY SELECTIVE NON-CATALYTIC REDUCTION SYSTEM (SNCR)
ASH MARKET
DISPOSAL
M
METERING PUMP(S)
INTERNAL BOILER
RECIRCULATION OF
SOLIDS DESULPHURIZED
BAGHOUSE FLUE GAS TO
OR ESP CHIMNEY
HYDRATOR
FEED ID FAN
HOPPER
SOLUTIONIZING
TANK SOLUTIONIZING UREA STORAGE
DISPOSAL MODULE TANK(S)
HYDRATED LIME FEED SCREW BYPRODUCT TO
DISPOSAL
WATER EXTERNAL
RECIRCULATION OF
SOLIDS DRY UREA CIRCULATION PUMPS
OPTIONAL FLYASH SOLUTIONIZING
FLUE GAS FROM PRE-COLLECTION EQUIPMENT
AIR PRE-HEATER
ESP
RECIRCULATION TO
ACHIEVE TURNDOWN
ASH MARKET
• Lower capital costs due to carbon steel absorber metallurgy and dry stack operation • Less complex to operate The SNCR process requires injection of urea into the flue gas within a temperature window of 1870-1090 °C to reduce NOX
• CDS Systems have shown SO2 removal efficiencies close to wet FGD systems • Requires a smaller footprint area than wet to nitrogen and water.
FGD • Very efficient at removing fine ash particles or sulphuric acid mist • Requires a new particulate removal device,
generally a new bag-house • Are limited in low-load operation
STATIC MIXERS
SORBENT DELIVERY FLOW
SORBENT STORAGE SORBENT STORAGE STRAIGHTENER
SILO SILO AMONIA
HEAT EXCHANGER OPTIONAL INJECTION
ECONOMIZER GRID CATALYST LEVEL 1
BYPASS CATALYST CLEANING SYSTEM
(SONIC HORNS, SOOT BLOWERS,
CATALYST LEVEL 2
DRYER AND/OR ASH SWEEPS)
BUTTERFLY
VALVES FUTURE CATALYST LEVEL
AIR
WEIGH WEIGH WEIGH WEIGH TO APH BOILER TEST GRID
FEEDER FEEDER FEEDER FEEDER OUTLET A LPA SCREEN
PRESSURE (SPARE)
BLOWER
ROTARY TO APH
TRUCK UNLOADING EQUIPMENT AIR LOCKS OUTLET A
ECONOMIZER
HOPPER
IN-LINE MILL
AIR TO ESP
OUTLET A
HEAT
DRYER EXCHANGER TO ESP FLUE GAS TO
OUTLET A AIR HEATER
(SPARE)
IN-LINE MILL
AIR
HEAT TO ESP
DRYER EXCHANGER OUTLET B AMMONIA
(SPARE) AMMONIA VAPORIZATION/
STORAGE TANK DILUTION
IN-LINE MILL
TO SCR
AIR OUTLET B
HEAT
DRYER EXCHANGER
TO APH
OUTLET B FORWARDING
3 x 50% PUMPS
TO APH
OUTLET B
(SPARE)
• Very low capital cost • Able to operate at all power plant loads • Can be used in conjunction with electrostatic SCR is a capital-cost-intensive, post-combustion technology that uses catalyst elements installed in the flue gas stream
precipitators (ESPs) • Limited in removal efficiency upstream from the air-preheater to promote the NOX reduction reaction.
4 5
Select References Select References
S&L has a record of providing continual and substantial environmental compliance services since the early 1970s. It has established Naughton 1 and 2 AQCS project - Clean Air Initiative
Leland Olds 1 and 2 FGD project, Stanton,
impressive and proven industry-recognised capabilities to provide integrated environmental and engineering services. Its experience
comprises assignments for more than 100 clients on hundreds of power plants in 26 countries across six continents, enabling North Dakota Program, Western U.S.
L&T-S&L to deliver projects efficiently. Select references are described below.
La Cygne Controls and Environmental Retrofits, Big Bend Units 1, 2, 3 and 4 SCR project,
La Cygne, Kansas Tampa, Florida
6 7
Select References Global Footprint
Conemaugh Units 1 and 2 SCR Project, Multi-system Air Quality Control Retrofit, L&T-S&L excels across the technology continuum, offering solutions for open/simple cycle plants, combined cycle plants,
New Florence, Pennsylvania Otter Tail Power, Milbank, South Dakota co-generation plants, and coal-based plants – subcritical, supercritical and ultra-supercritical technology. Advanced modeling
techniques and cutting-edge IT further reinforce the Company's capabilities to deliver effective solutions that meet client objectives.
The L&T-S&L footprint has been growing globally. The maps below indicate a few of our project locations.
Otter Tail Power Company authorised S&L to engineer a
This was an1800 MW supercritical power plant at New major AQCS retrofit project at their Big Stone Plant. S&L
Florence Pennsylvania, based on bituminous coal. S&L's was awarded this project based on their credentials and
scope included preliminary engineering and development competitive bid.
of the project cost estimate and schedule; detail design
of the foundations, structural steel and BOP for the SCR This 495 MW Powder River Basin (PRB) coal-based AQCS
retrofit, start-up and commissioning. This scope also project included a circulating type dry FGD system, new
included the procurement of the SCR reactors, SCR baghouse to replace the existing installation, an SCR
ductwork and replacement of ID booster fans, plant system, boiler modifications for separated overfire air
start-up transformer and 13.8-kV switchgear. For the and an ACI system for mercury control. S&L's scope
remaining BOP, S&L prepared specifications for the encompassed permitting support, detail design,
system and equipment. procurement, construction and start-up support.
Dry Fork Station Unit 1 SCR Project in Gillette, PACO Units 1 and 2 FGD Project Punta Rincon,
Wyoming Panama
Duke Cayuga, Gibson and Miami Fort Hayden Unit 1 SCR Project in Colorado
FGD projects
This 205 MW Hayden Unit 1 is in compliance with the
Over the past eight years, S&L supported Cinergy with latest legislatively-imposed Clean Air-Clean Jobs Act in
the development of an environmental compliance Colorado. S&L has been responsible for strategic
planning strategy for nitrogen oxides (NOX), sulphur planning and conceptual design, procurement of SCR
dioxide (SO2), mercury (Hg) and particulate control for and detail design of BOP. Additional controls to further
their Indiana, Kentucky and Ohio generating stations. reduce nitrogen oxide emissions at Hayden will also be
The compliance strategy for NOX resulted in the installed on the Unit, making Hayden one of the
installation of a total of eight SCRs at the 1060 MW cleanest coal-fired generating stations in the region
East Bend (1), 1950 MW supercritical Gibson (5) and with advanced emissions-control equipment.
1100 MW Miami Fort (2) stations. The Selective
Catalytic Reduction (SCR) program began with initial
engineering in 1999 and was completed in 2003, when
the last of the eight SCR systems went into operation at
the Gibson Station. S&L's scope included design
optimisation studies, FGD technology island
development and procurement, Balance-Of-Plant (BOP)
interface design and procurement, site arrangement Domestic Footprint in India
drawings, site development/underground utilities, Detail Engineering
capital and O&M cost estimates and project schedules. Coal-based Projects > 21,000 MW
Gas-based Projects > 3,000 MW
Owner's Engineering
Coal-based Projects > 10,500 MW
Gas-based Projects > 300 MW
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Contact Us
CBMC/PRD/072016
A joint venture of Larsen & Toubro Limited and Sargent & Lundy LLC
Registered Office: L&T House, N. M. Marg, Ballard Estate, Mumbai 400 001, INDIA
Website: www.Larsentoubro.com CIN: U74210MH1995PLC088099