EXECUTIVE SUMMARY Todays strict environmental regulation requires power plant operators to reduce their harmful emissions.

Sulfur Dioxide (SO2) is one of emission produced from boiler combustion that can create acid rain. This acid rain is very harmful both to the human health and environment. It contributes to environment damage, increased illness and premature death from heart and lung disorder. Flue Gas Desulfurization is a system used to remove the emission of Sulfur Dioxide (SO2) in combustion flue gas emitted by Coal fired power plant.Typically FGD system is capable to remove approximately 80% of SO2emission from the flue gas stream. The by-product of FGD system is gypsum (CaSO4) which can be used for various industrial applications. PLTU Tanjung Jati B, a relatively new power plant with net capacity of 4 x 660 MW, operates all of its boilers with FGD. In normal operating conditions, the exhaust gas emitted to the environment consists of CO2, H2O,NOx, and a small part of SOx. However, recently Tanjung Jati B Unit 1&2 FGD system started toexperience malfunction, causingenvironmental and operational problems. The problem causes carryover of salt and gypsum in the flue gas resulting in local salt rain. This situation is harmful tothe

agricultural fieldsaroundthe plant, creates a corrosion problem and corona problem to the high voltage equipment. Due to the aforementioned problems, the FGD system must be periodically maintained and as consequences, the corresponding power plant unit also has to be shut down. In this paper, schematic of FGD system in Tanjung Jati B power plant Unit 1&2, the working principle of FGD, chemical processes inside FGD system, and the phenomena that can cause the malfunction of the FGD are explained in detail. The focus of this paper is the operation within the FGD absorber system. The solution to the FGD problem and proposed

improvement for FGD operation are described in order to maintain proper operation of FGD and availability of the power plant.

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I INTRODUCTION
I.1 Background Tanjung Jati B Power Plant is one of the biggest Coal Fired Power Plant (CFPP) in Java Bali system. It has 4x660MW net generating capacity and contributes to approximately 11% energy in Java Bali Madura Electricity system. The availability and reliability of Tanjung Jati B greatly impacts the system and the soundness of operation condition of the aforementioned system. Tanjung Jati B Power Plant Consumes mostly Medium Calorific Value (MCV) Coal approximately 6750 ton/day per unit, and produce large amount of fly/bottom ah, CO2, SO2, NOx, etc. These by products contribute significantly to acid rain formation. As widely known, acid rain is very harmful forthe environment and human health.

Figure1 :Tanjungjati B Power Plant Units 1-4 One of the equipment that can be used to reduce SO2 emission is the Flue Gas Desulfurization (FGD) system. FGD system can reduce the amount of SO2 emitted to the environment by method of wet scrubbing of the flue gas using limestone slurry. In Coal Fired power Plant, FGD system is installed between Electrostatic Precipitator and exhaust Stack. A single FGD in Tanjung Jati B power plant is capable of removing 516,24 kg SO2 per hour

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contained in the flue gas. Figure 2 shows the schematic of FGD in Tanjung Jati B Power Plant.

FGD System

Figure2 : Location of FGD in Coal Fired Power Plant System

Figure 3 :TanjungJati B Unit 2 FGD Absorber

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Mist Eliminator Area

Treated Flue Gas SO2 Scrubing Area

Inlet Flue Gas (SO2)

Forced Oxidation Area

Figure 4 : Typical FGD Schematic. Oxidation air system does not reflect configuration in FGD unit 1&2 Figure 4 shows the layout of FGD absorber. This system is the main equipment in FGD system, that functions as SO2 absorber, and gypsum producer. The absorber is divided into several areas. SO2scrubbing area absorbsSO2from flue gas stream and converts it into Calcium Sulfite (CaSO3). Mist eliminator area filters slurry carryover in the flue gas stream. The forced oxidation area oxidizes Calcium Sulfite into Calcium Sulfate/Gypsum (CaSO4) by supplying air oxidation air. The operating principle of FGD absorber is as follows: 1. Flue Gas from ESP (Electrosatic Precipitator) enters the FGD and is scrubbed by Limestone Slurry to remove SO2content, creating Calcium Sulfite (CaSO3). 2. The Flue gas flows through mist eliminator for removal of slurry carry over. The treated flue gas exiting the eliminator has low level of SO2 and solid particles, and is ready to be safely exhausted to the environment. 3. The limestone and calcium sulfite slurry that is used to scrub the flue gas drops into the Forced Oxidation area, which is then converted into Gypsum.

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4. Gypsum from the Forced oxidation area is continually removed to separator area to be dried and shipped. The reaction taking place in wet scrubbing using a CaCO3(Limestone) slurry produces CaSO3 (calcium sulfite) and can be expressed as: CaCO3 (s) + SO2 (g) CaSO3 (s) + CO2 (g) The CaSO3 (calcium sulfite) is further oxidized to produce CaSO4 2H2O (Gypsum) via forced oxidation method: CaSO3 (s) + H2O (l) + O2 (g) CaSO4 (s) + H2O

Figure 5 : FGD Absorber Reaction Schematic In Tanjung Jati B, The average SO2 concentration in flue gas entering the FGD absorber is 1500ppm. The typical FGD exhaust SO2 level is approximately 300ppm. Thus, the condition meets the environment regulation forSO2emission which must be less than 750 ppm.The limestone consumption needed depends on the SO2 production which affected by coal quality and quantity. In common operation, Tanjung Jati B consume approximately 2500-3000 ton of limestone per month per Unit operation. I.2 Problems Experienced In TanjungJati B FGD Unit 1&2 One of the problems experienced in FGD system is due to salt and gypsum carry over caused by mist eliminator malfunction. When the mist eliminator performs under malfunction
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operation, the solid material in flue gas could not be filtered and released to the environment along with the flue gas. The material carried over from FGD causes environmental problem and become a big issue. The corrosive and pollutant characteristic of the carry over material contributes to equipment corrosion and damage. Carryover also cause corona problem to the high voltage equipment forcing shutdown of the unit to conduct insulator cleaning. Due to the current condition, proper operation of FGD is strongly needed, and improvement must be established to perform the excellence unit operation. I.3 Benefit The improvements proposed aims to improve FGD system in order to increase reliability, availability and long life operation capability of the unit. The aim of improvement is to provide sustainable and economic electric energy supply with consideration of environmental aspect. It is important for Tanjung Jati B Power Plant to perform safely, reliable and environmentally friendly. I.4 Purpose The purpose of the improvement modification is to provide solution and improvement in order to maintain proper FGD operation.

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II. CONTENT
The chemical reaction taking place in FGD absorber system is a delicate process that requires control of limestone slurry supply, PH level, oxidation air supply, and sulfite build up.All aspects must be properly controlled to maintain adequate SO2 absorption, and acceptable parameters within the FGD system. Despite efforts to control these parameters, there are several operational problems experienced in unit 1&2 FGD due to incorrect operating parameters. The said problems are as follow; Increase of Sulfite level in Absorber Sulfite Blinding causing Occasional Temporary Inability of SO2 Removal and loss control of PH Hardening of Slurry matter in FGD Absorber. Frequent Inability of FGD to filter carry over into exhausted flue gas.

Details of the aforementioned problems are explained in subchapters III.1 to III.4. II.1 Increase of Calcium Sulfite level in Absorber The absorber is designed to remove sulfur dioxide emission of 516,24 kg/hr by converting SO2 into Calcium Sulfite (CaSO3) The Calcium sulfite is then turned into Calcium The Limestone forced oxidation

Sulfate/Gypsum (CaSO4) by forced oxidation method.

system typically has a very low concentration in dissolved Calcium Sulfite, with typical concentration less than 30 ppm. The sulfite level can be controlled by supplying oxidation air to the forced oxidation area, by means of Air blower and diffusers in the bottom of the Absorber. Despite the typically acceptable Calcium Sulfite conditions, increase in Calcium Sulfite concentration can occasionally occur in FGD absorber. This is caused by lack of oxidation air amount in relation with the Calcium Sulfite added into the forced oxidation system. The cause oflack of supply is insufficient air supply from the oxidation blower, blocking of oxidation air holes in the absorber, and elevated SO2 level in flue gas beyond the capability of the absorber.

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Figure 6 :Hibbon air blowers supplying oxidation air to FGD absorber The condition mentioned above causes theCalcium Sulfite to Gypsum reaction to be incomplete, and leaving a fraction of sulfite not converted, thus gradually increasing sulfite concentration. Increase in sulfite concentration can be detrimental towards FGD operation because it leads to other problems, such as Sulfite Blindingand Hardening of Slurry Matter that will be explained in the next subchapters. Shown in figure 6 and 7 are photos of one of oxidation air pipe blockage, reducing absorber capability to oxidize Calcium Sulfite into Gypsum.

Figure 7: Blocked oxidation air nozzle. In operating condition, this pipe is submerged in gypsum slurry Shutting down of oxidation air will result in slurry entering the pipes and increase chance of blockage.
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Figure 8 : Removed Oxidation Air pipe containing solid gypsum blockage II.2 Sulfite Blinding Sulfite Blinding is a phenomenon characterized by loss control of Absorber PH, regardless of increased supply of limestone slurry. This situation is caused by increase of sulfite

concentration in the absorber. At some concentration, there is enough sulfite to start blinding the limestone. In the area around a calcium carbonate particle (the active ingredient in limestone) there is a relatively high PH in the range of 6-8. The bulk of the slurry is typically in a PH range of 5.2 to 5.6. The solubility of calcium sulfite decreases with increasing PH. This causes sulfite to precipitate into surface of limestone and reduce the active surface area of limestone, thus resulting in loss control of PH.

Figure 9: SEM photograph of Calcium sulfate (flat plates) blindunreacted limestone. The elevated concentration of calcium sulfate will cause the inability of limestone to convert SO2into Calcium Sulfite.
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Sulfite Blinding will reduce the ability of Limestone slurry to convert SO2into Calcium Sulfite, causing addition of SO2instead of Calcium Sulfite in the forced oxidation area. Introduction of SO2into the forced oxidation area will continually decrease the PH level due to the inherent acidity of SO2. Adding limestone will not increase the PH, it will make the problem worse. Also, the flue gas exhausted into the environment will not be properly treated, and contains high level of SO2. II.3 Hardening of Slurry matter in FGD Absorber Due to its flat molecular shape, Calcium Sulfite is prone to form solidmaterial and scale in the FGDabsorber. This condition will createundesirable operating condition and can threat the FGD operation. The hardened material needs to be removed, and shutting down of FGD is necessary toperform the action.

Figure 10: Large amount of scales and hard material removed from Unit 1 Absorber.

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Figure 11: The scale collected from FGD absorber was large and had may layers II.4 Frequent Inability of FGD to filter carryover material The most known problem of Unit 1&2 FGD is carryover of Gypsum and Salt in the exhausted flue gas. The FGD design to filter the carry over by series of tight chevrons called the Mist Eliminator. The chevron filters the carry over material, and is periodically sprayed every 15 minutes to drop the carry over into the forced oxidation pool.

Figure 12: Mist eliminator profile

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The carry over problem is caused by blocking of mist eliminator by carry over material, rendering it ineffective to properly function. One of the causes is blockage of spray nozzle due to barnacle Shells carried bysea water supply. This leaves parts of eliminator being unwashed, leaving residual material carried by flue gas. Another cause of blockage is the

occasional increase in Calcium Sulfite that increases the chance of solid formation in the mist eliminator. Both of these factors contribute in the ineffectiveness of mist eliminator causing unavoidable carry over.

Figure 13: Properly working Mist Eliminator Spray Nozzle

Figure 14: Mist eliminator Nozzle block by seashell

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Figure 15: Major Blockage on mist eliminator by slurry II.5 Secondary Problems caused by improper condition of FGD The improper FGD condition also cause environmental problem within and outside of the Power Plant area, mainly due to Carry Over in flue gas. The environmental problems are as follow; Gypsum Carry over creating corrosion problem in units 1to4 Gypsum carry Over creating corona problem in high voltage isolators Gypsum Rain causing crop failures in neighboring crop fields, resulting in an environmental and Public Relations problem.

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III CONCLUSION AND RECOMMENDATIONS Analysis of the situation results in these factors as cause of problem; Elevated SO2 concentration in flue gas beyond the capability of FGD. Lack of oxidation air supply Blockage of Mist Eliminator Blockage in mist eliminator spray Blockage in oxidation air nozzle

Based on analysis on the situation, the following actions are proposed to relieve the situation. Utilization of fresh water instead of sea water for supply of Mist eliminator spray. Replacement of oxidation air system with new design to eliminate blockage. Increase of oxidation air supply.

Details of the aforementioned improvement solutions are explained in subchapters IV.1 to IV.3. III.1 Utilization of fresh water to supply of Mist eliminator spray Fresh water can be utilized to supply mist eliminator spray, replacing sea water as current supply. The main purpose is to eliminate blocking of nozzle by seashell. Several

modifications need to be done to achieve this such as rerouting of supply water, and new piping. III.2 Improvement of oxidation air system design The purpose of the existing oxidation system is to create small bubbles via small pipe holes, creating a large contact area to optimize forced oxidation reaction. However, the existing system is prone to blockage, rendering the forced oxidation to be less effective. This can be relieved by employing a new design, which utilizes agitators instead of small holes to diffuse the oxidation air. Such system is installed in Tanjung Jati B FGD for Unit 3&4. Figure 15 shows illustration of the proposed improvement.

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Oxidation air supply with agitators as diffuser

Figure 16: Improved oxidation air system as employed in Tanjung Jati B FGD absorber unit 3&4 III.3 Increase in oxidation Air Supply It is understood that coal supplied to Tanjung Jati B Power Plant has high sulfur content. This results in high SO2 emitted into the FGD to sometimes rise above 2000ppm. The oxidation air of the FGD is not sufficient to convert the elevated Sulfite concentration due to high SO2, and will increase sulfite level resulting in Sulfite Blinding. This situation can be relieved by increasing the supply of oxidation air, by adding bigger air blowers. III.4 Conclusion The appropriate application of the proposed improvements will reduce the intensity of the aforementioned malfunction, and improve the condition of Tanjung Jati B FGD System. This is made possible because the improvements eliminate the root cause of the problem. Such improvements are most needed to ensure excellent operation of the Power Plants.

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