ACID GAS CONTROL (SCRUBBERS)

Spray Dryer Absorbers

Spray dryer Absorber (SDA) for SO2 removal and acid gas control

Features

Overall design is simple, reliable and robust

  • No special tools required
  • No high speed rotary atomizers


Operational Flexibility

  • Online system maintainability without decreasing boiler load
  • Continuous acid gas emissions performance even when multiple nozzles are taken out of service
  • High turndown capability (25% MCR) without recirculation
  • Fast load response
  • Wide range of acid gas control


Low maintenance labor and material costs

  • Minimal cleaning, up to 3 weeks continuous operation

Our Spray Dryer Absorber (SDA) system is especially well suited to control SO2 and acid gas emissions. Our large utility and industrial fleet is installed at a wide range of facilities ranging from power plants, waste-to-energy plants, and hazardous waste plants.

SDA designs can range from truck shippable industrial designs to larger absorbers suitable to utility exhaust gas flows.

  • The new generation of SDA nozzles now available has significantly reduced cleaning frequency.
We have installed over 60 SDA units representing over 4,500 MW of plant capacity.

Applications

Power Plants

Coal

Pet Coke

Lignite

Municipal Solid Waste (MSW)

Hazardous waste

Biomass (Medical Waste)

Reactive Waste

Wood

Tires

Miscellaneous

Flue Gas Cooling

Water Evaporation (Zero Liquid Discharge)

Pond Water Remediation

How it Works

Spray Dryer Absorber (SDA) technology is designed to provide acid gas and solid particulate control utilizing alkaline slurry, typically lime.  The slurry is atomized into fine droplets which are dispersed into the flue gas within the SDA. 

Spray dryer absorber (SDA) how it works and acid gas control

The fine spray provides increased contact area in order for mass transfer to occur.  Evaporation of the slurry water in the droplets occurs simultaneously with mass transfer which cools the flue gas. 

The cooled flue gas carries the dried reaction product downstream to a particulate collection device, typically a fabric filter (FF).

Special Features

SDA two fluid nozzles for SO2 control

TWO FLUID NOZZLE DESIGN

The key to efficient performance is the means used to atomize the lime slurry into droplets within the gas stream. The SDA utilizes a two-fluid nozzle to atomize the lime slurry.

  • Low maintenance labor and material cost, no costly gear box overhauls
  • No special tools required

    • Nozzle maintenance takes less than 10 minutes
  • Online system maintainability without decreasing boiler load
  • Continuous acid gas emissions performance even when multiple nozzles are taken out of service

    • Lower parasitic load
  • Lower absorber pressure drop
  • Single compressor versus multiple rotary atomizers

SDA two fluid nozzle for sulfur dioxide control

OPTIMIZED TWO FLUID NOZZLE DESIGN RELEASED

Industry experience with earlier SDAs was they were expensive to operate and maintain regardless of the atomization mechanism used. We have redesigned our two-fluid nozzle to improve the distribution and mixing of atomizing air with lime slurry, which improves mixing efficiency and decreases operating and maintenance costs.

The optimized nozzle design delivers even atomizing air distribution to produce a consistent droplet size while providing longer nozzle life. In 14 field applications, the optimized nozzle has demonstrated low cleaning frequency (1 to 3 weeks continuous operation), reduced cost of operation (20 to 25% less compressed air consumption), and longer life with its new tungsten carbide inserts.


Operational flexibility

The SDA design provides operating flexibility for the entire plant. For example, any two fluid nozzle can be removed for maintenance without decreasing boiler load.  Emissions performance is maintained even when multiple two-fluid nozzles are taken out of service.


HIGH UNIT TURNDOWN

The SDA is capable of high unit turndown, down to 25% of rated flue gas flow without recirculation of the flue gases while maintaining emission requirements.


FAST LOAD RESPONSE

The design of the unit also provides for fast load response enabling unit cycling or load following.

Recent Projects

Spray dryer abosrber (SDA) at baldwin facility
BALDWIN GENERATING STATION, UNITS 1 – 3

Location: Baldwin, Illinois, USA
Customer: Dynegy, Inc.
Start-Up Year 2010 / 2012
Capacity: 3 x 600 MW
Fuel: PRB Coal
AQCS Configuration: Two (2) x 50% SDA/PJFF per Unit
Gas Flow: 6 x 1,232,500 (6 x 2,094,000 m3/h)"
SO2 Removal: Up to 95%

Spray Dryer Absorber (SDA) at waste-to-energy facility
NORTH COUNTY RESOURCE RECOVERY FACILITY, UNITS 1 AND 2

Location: West Palm Beach, Florida, USA
Customer: Solid Waste Authority of Palm Beach County
Start-Up Year 2011
Capacity: 2 x 1150 tons/day
Fuel: Municipal Solid Waste (MSW)
AQCS Configuration: One (1) SDA/PJFF per Unit
Gas Flow: 2 x 240,000 ACFM (2 x 407,800 m3/h)"
SO2 Removal: Up to 75%

Spray dryer absorber (SDA) Lon D. wright power plant
LON D. WRIGHT POWER PLANT, UNIT 8

Location: Fremont, Nebraska
Customer: City of Fremont Department of Utilities (FDU)
Start-Up Year 2015
Capacity: 90 MW
Fuel: PRB Coal
AQCS Configuration: One (1) SDA/PJFF
Gas Flow: 413,000 ACFM (701,700 m3/h)
SO2 Removal: Up to 90%

Spray dryer absorber at jacksonville florida (JEA)
JEA NORTHSIDE GENERATING STATION (NGS), UNITS 1 & 2

Location: Jacksonville, Florida, USA
Customer: JEA
Start-Up Year 2002
Capacity: 2 x 300 MW
Fuel: Pet Coke & Coal
AQCS Configuration: One (1) x 100% SDA/PJFF per Unit
Gas Flow: 2 x 860,000 ACFM (2 x 1,461,100 m3/h)
SO2 Removal: Up to 95%

Talk with a technical specialist

Your questions are our priority. Contact us at 412.562.7300 or add your question below and we’ll be in touch.