Utility-Scale SO2 Eradication | BLSHSTL1W/230W Series Limestone-Gypsum Flue Gas Desulfurization

🌊 Volumetric & Load Capacity

• 📉 Max Gas Volume: 10,000 to 2,300,000 m³/h
• 🌡️ Gas Temperature: Up to 180 °C
• 🌫️ Max Inlet Sulfur: 1 to 5000 mg/Nm³
• ⚖️ Casing Pressure: -6000 to +6000 Pa

🎯 Purification Performance

• ✅ Outlet Emission: < 35 mg/Nm³
• ✅ Operating Resistance: 800 – 1300 Pa
• ✅ Desulfurization Efficiency: > 98.5%
• ✅ Byproduct: High-Purity CaSO₄·2H₂O

🏭 Target Heavy Industries

• ⚡ Utility Power Generation: Large capacity units
• 🏗️ Metallurgy: Sinter plant high-flow exhausts
• 🏭 Cement & Kilns: High-dust, high-sulfur applications
• ♻️ Commercial Recovery: Plasterboard/Cement additive generation

The Limestone-Gypsum Reaction Mechanism

The Ever-power WFGD process relies on a continuous, violently agitated, gas-liquid-solid multiphase reaction. Raw flue gas enters the absorber from the bottom and flows upward, making counter-current contact with the limestone slurry sprayed downward.

1. Absorption & Neutralization:
SO₂ + H₂O → HSO₃^– + H⁺
SO₃ + H₂O → H₂SO₄
CaCO₃ + H₂O → Ca²⁺ + OH^– + CO₂
The acidic components are rapidly absorbed by the water and neutralized by the dissolved calcium ions, forming Calcium Sulfite (CaSO₃).

2. Forced Oxidation:
HSO₃^– + O₂ → 2SO₄^2- + 2H⁺
Oxygen injected into the lower slurry tank by Roots blowers oxidizes the unstable sulfite into stable sulfate.

3. Gypsum Crystallization:
Ca²⁺ + SO₄^2- + 2H₂O → CaSO₄·2H₂O
The sulfate combines with calcium and water to precipitate as Calcium Sulfate Dihydrate (Gypsum), which is pumped out via hydrocyclones and vacuum filters for commercial sale.

Heavy-Duty Internal Components

• Absorber Body: Forged from Carbon Steel with a rigorous, multi-layered Glass Flake anti-corrosion coating to survive decades of abrasive slurry and acidic gases.
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• Slurry Spray Layers: Composed of advanced atomizing headers utilizing Silicon Carbide (SiC) nozzles. These nozzles sheer the slurry into fine droplets (200-500 μm), creating a massive specific surface area for the chemical reaction while resisting aggressive abrasion.
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• Alloy Trays (Sieve Plates): Installed below the spray layers, these porous alloy trays force the ascending gas to bubble violently through a suspended layer of slurry, drastically amplifying gas-liquid mixing and enhancing mass transfer efficiency.
• Oxidation System: Dedicated Roots blowers inject pressurized oxidation air into the slurry pool. Side-entry Agitators relentlessly stir the pool, preventing dense gypsum from settling and ensuring 100% oxidation of the slurry.
• Multi-Stage Demister: Two tiers of chevron demisters strip entrained liquid droplets from the purified gas. An integrated Demister Flushing system prevents gypsum scaling on the blades.

Absolute Anti-Corrosion Mastery

The interior of a WFGD tower is one of the most hostile environments in heavy industry, characterized by high chlorides, low pH, and abrasive solids. Ever-power utilizes proprietary vinyl ester glass flake linings and highly specified duplex stainless steels to guarantee a 20+ year lifespan without shell degradation.

Unparalleled Desulfurization Efficiency

Through advanced Computational Fluid Dynamics (CFD), we optimize the placement of the Alloy Trays and SiC spray nozzles. This ensures an incredibly uniform Liquid-to-Gas (L/G) contact ratio across the entire massive diameter of the tower, consistently delivering >98.5% SO₂ removal.

Zero-Blockage Operation

Scaling and plugging are the death knell of poorly designed calcium scrubbers. Our high-velocity circulation pumps, aggressive agitation systems, and perfectly sequenced demister flushing protocols ensure that gypsum crystallizes in the slurry pool, not on your critical internal components.

The Nightmare of Internal Scaling & Plugging

Sub-par limestone scrubbers suffer from severe calcium sulfite/sulfate scaling. Nozzles plug, spray coverage drops, and SO₂ emissions spike. Demisters become caked in concrete-like gypsum, choking off gas flow and tripping the main boiler’s ID fans. This leads to multi-million dollar unplanned outages where maintenance crews must manually jackhammer scale out of the tower.

Crippling Regulatory & Fuel Constraints

Environmental policies enforce brutal fines for exceeding 35mg/Nm³ SO₂ limits. If your current FGD system is inefficient, you are forced to burn highly expensive, low-sulfur premium coal just to stay compliant. A highly efficient Ever-power WFGD allows your procurement team to buy cheaper, high-sulfur coal, instantly transforming your plant’s profitability matrix.

Utility-Scale Power Generation

The standard-bearer for 300MW to 1000MW+ coal-fired power plants. Handles extreme volumetric flows and fluctuating loads while maintaining unwavering compliance with grid emission telemetry.

Steel Sintering Plants

Sintering exhaust contains a highly complex mix of SO₂, heavy metals, and abrasives. Our heavy-duty SiC nozzles and glass-flake linings easily absorb the punishment of metallurgical exhaust streams.

Commercial Gypsum Operations

For plants looking to completely close the circular economy loop. The Ever-power WFGD system includes advanced hydrocyclone and vacuum belt filter designs to produce high-purity ( >90% ) commercial-grade gypsum for the cement and plasterboard industries.

For over two decades, Ever-power has been the structural backbone of heavy industrial air purification. Designing a mega-scale WFGD plant is a multidisciplinary engineering marvel involving chemical reaction kinetics, fluid dynamics, and advanced materials science. It cannot be outsourced to generalists.

• ✔️ End-to-End EPC Mastery: We execute the entire project lifecycle: Process R&D Design ➔ Heavy Fabrication ➔ Massive On-Site Erection ➔ Intelligent Commissioning.
• ✔️ Trusted by Heavy Industry Giants: Our bespoke BL Series protects the core operations of leading conglomerates worldwide, including Shanshui Group, Huarun Power, and Tongchuan Shengwei.
• ✔️ Uncompromised Quality Credentials: Fully ISO certified, holding dedicated structural and chemical patents for optimized spray arrays and advanced slurry agitation technology.

The Cost of Subpar FGD Systems

• Fuel Cost Strangulation: If your scrubber cannot handle heavy sulfur loads efficiently, your procurement team is forced to purchase highly expensive, low-sulfur premium coal just to meet emission limits.
• Catastrophic Outages: Poor fluid dynamics lead to slurry settling, nozzle plugging, and demister scaling. A forced shutdown of a 600MW boiler to manually clean a scaled absorber costs millions in lost electrical sales to the grid.

The Ever-power Upgrade ROI

• Fuel Flexibility Freedom: With robust buffer capacities up to 5000 mg/Nm³, your plant can aggressively source cheaper, high-sulfur coal, saving tens of millions in annual fuel OPEX.
• Gypsum Revenue Stream: Complete oxidation and precision vacuum dewatering transform toxic SO₂ into high-purity commercial gypsum, creating a steady, lucrative secondary revenue stream from the construction industry.
• Unwavering Reliability: Advanced glass flake linings and zero-plug SiC nozzles ensure the absorber runs continuously from planned outage to planned outage, maximizing your plant’s capacity factor.

🇮🇳 Jindal Mega Power Plant (India)

Application: 2x 660MW Coal-Fired Utility Boilers

Challenge: The plant transitioned to burning highly abrasive, high-sulfur local lignite coal. Previous scrubber linings were failing within 18 months, causing massive leakage and compliance failures.

Solution: Installed dual Ever-power BLSHSTL Series absorbers featuring monolithic glass-flake linings and specialized alloy agitators. Maintained >99% SO₂ removal and <35mg/Nm³ outlet emissions. Zero lining failures reported after 5 years of continuous base-load operation.

🇻🇳 Hoa Phat Steel Complex (Vietnam)

Application: 400m² Iron Ore Sintering Machine

Challenge: Sintering exhaust features highly fluctuating volumetric flows and elevated chloride levels which aggressively corroded standard 316L stainless steel internal components.

Solution: Ever-power engineered an advanced WFGD using 2205 Duplex Stainless Steel for all critical internal wetted parts (trays, spray headers). The system successfully handled the aggressive metallurgical exhaust, recovering commercial-grade gypsum for local cement plants.

🇨🇳 Huarun Power Cogeneration (China)

Application: 350MW Heat and Power Unit

Challenge: Required strict “ultra-low emission” compliance to operate near urban centers, demanding SO₂ emissions to never spike during load following operations.

Solution: Retrofitted with Ever-power’s high L/G ratio spray arrays and optimized Alloy Trays. The enhanced gas-liquid contact time achieved stable emissions hovering around 15 mg/Nm³, easily passing state environmental audits.

🇧🇷 Votorantim Cement Kiln (Brazil)

Application: 5000 TPD Clinker Kiln Exhaust

Challenge: Extremely high dust loads bypassing the upstream ESP were turning the WFGD slurry into thick mud, plugging standard circulation pumps.

Solution: Deployed heavy-duty, polymer-lined, open-impeller circulation pumps and high-velocity SiC nozzles. The robust fluid handling design easily processed the dense slurry without clogging, ensuring kiln uptime.