Advanced Technology to control PM, Nox, VOCs in a cost effective - - PowerPoint PPT Presentation

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Advanced Technology to control PM, Nox, VOCs in a cost effective - - PowerPoint PPT Presentation

Dec 26, 2023 175 likes •685 views

Advanced Technology to control PM, Nox, VOCs in a cost effective Manner .. Presented by : SACHIN PANWAR 1 Table of Content Why Clean the flue gas ? Why VOCs, Nox, SOx, PM are Threat? Haldor Topsoe in Brief Topsoe

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Advanced Technology to control PM, Nox, VOCs in a cost effective Manner… ..

Presented by : SACHIN PANWAR

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Table of Content

  • Why Clean the flue gas ?
  • Why VOCs, Nox, SOx, PM are Threat?
  • Haldor Topsoe in Brief
  • Topsoe Solution Range
  • Catalytic Process Fundamental Steps
  • Topsoe Environmental solution.
  • Catalytic Filtration technology
  • Conclusion
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Why Clean the Flue Gas?

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4

Major Contributing Factors

For Air Pollution

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Daily cycle of pollutant concentration

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Why VOCs, NOx ,SOx, PM are threat?

  • Forms ground level ozone (or smog)
  • Triggers asthma attacks and cancer
  • Contributes to acid rains
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Haldor Topsoe in brief

  • Established in 1940 by Dr. Haldor

Topsøe.

  • Private 100% family-owned company.
  • Market leader in heterogeneous catalysis

and surface science for over 70 years.

  • Around 2,800 employees in 11 countries

across 5 continents.

  • Headquarters in Lyngby, Denmark.
  • Spends more than 10% of revenue on

R&D.

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Headquartered in Denmark,

  • ur 2,800 employees work with customers all over the globe

Locations: Bahrain Beijing Buenos Aires Cape Town Copenhagen Edmonton Houston J

  • inville

Kuala Lumpur Los Angeles Moscow New Delhi Rio de J aneiro Tianjin H P E S Headquarters Production Engineering Sales & Service

P E S S S P E S H E S S S S S P S S P E

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Emissions Management

We provide a full range of products and services for a broad range of business

Chemical Processing Hydroprocessing

Ammonia Syngas Methanol Hydrogen SNG Sulfuric acid Dimethyl ether Formaldehyde Gasoline synthesis Naphtha Kerosene Diesel VGO Resid Sulfur removal NOx & CO removal VOC abatement Particulate filtration

Process design, Engineering, & licensing High-performance catalysts

+

Proprietary equipment

+

Business & technical services

+

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Catalytic Process- Fundamental steps

Gas phase transport and pore diffusion of educts

  • 1. Step

Adsorption of educts

  • 2. Step

Surface reaction

  • 3. Step

Desorption of products

  • 4. Step

Gas phase transport and pore diffusion of products

  • 5. Step

Reactant Products

+ +

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Haldor Topsoe Solution

For Environment Protection

T echnology to transform sulfur pollutants into sulfuric acid Catalysts to clean the vehicle exhaust T echnologiyto remove nitrogen oxides T echnology to treat volatile organic compounds

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A process for cleaning sulfur containing streams under production of concentrated sulfuric acid

Wet gas Sulfuric Acid H2SO4

Lean H2S gas Rich H2S gas SRU tail gas SWS gas SO2 SO3 Spent H2SO4

WSA

Cleaned gas HP Steam

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WSA process lay-out, H2S gas

H2S gas

SO2 Converter Acid cooler

Product acid Combustion air Stack gas

Blower WSA Condenser Interbed cooler Interbed cooler Gas cooler Combustor

Air

Blower

Reaction: H2SO4 (g) → H2SO4 (liq) Reaction: SO3 + H2O → H2SO4 (g)

BFW

Steam Drum WHB

Reaction: SO2 + ½O2 → SO3 Reaction: H2S + 1½O2 → SO2 + H2O

CW Superheated steam

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Topsoe Vanadium SCR for Indian automotive market

  • Very good low temperature conversion
  • Full-body, unlike coated SCR
  • Best in class dynamic response to transient

conditions

  • Best in class sulfur tolerance, due to high

porosity substrate

  • Low deactivation over time
  • Lowest weight
  • Zone coated ASC, if needed
  • Available in diameters 7.5” - 17”
  • Proven technology for

Euro IV/V/VI and Tier4i/f

  • Proprietary substrate,

no dependancy on substrate manufacturers

  • Local engine test and production

planned

  • Mechanical durability, simple canning
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Catalytic combustion process

General

10 20 30 40 50 60 70 80 90 100 50 100 150 200 250 300 350 400 450 Temperature (oC) Conversion (%) Carbon monoxide Methanol Toluene Chlorobenzene n-Hexane Ammonia

VOC + O2 = CO2 + H2O

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Oxidation catalyst portfolio

> 500 references

Type Application

CK- 302/322 CKM-2x CKM- 3324 Cu-Mn Hydrocarbons, hydrocarbons with

  • xygen and nitrogen. Silicon and

bromine resistant CK-304 CKM-3x, DNOC Pd Aromatics, CO, hydrogen, ammonia, short-chained alkanes CK-305 CK-395 Cr Mn Halogenated hydrocarbons CK-306 Cr-Pd Halogenated hydrocarbons, CO CK-307 Pt All hydrocarbons, CO, sulphur compounds (<200 ppm) CK-428 Cu-Mn Pt Sulphur compounds (>200 ppm), ammonia

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SCR DeNOx Technology

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Chemical Reaction

  • 6 NO + 4 NH3 → 5 N2 + 6 H2O
  • 6 NO2 + 8 NH3 → 7 N2 + 12 H2O

O2 makes the reaction faster Me=Vanadium or Tungsten Mechanism:

  • Adsorptions mechanism
  • Elay-Rideal mechanism
  • Langmuir-Hinshelwood

mechanism

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(1) NH3 + V5+-OH ↔ V-ONH4 (2) V-ONH4 + V=O ↔ V-ONH3-V4+-OH (3) NO + V

NO + V-ONH ONH3-V4+

4+-OH

OH → N2 + H + H2O + V O + V5+

5+-OH

OH + V + V4+

4+-OH

OH

(4) 2V4+-OH ↔ H2O + V3+ + V=O (5) O2 + 2V3+ → 2V=O (6) H2O + V5+-OH ↔ V5+-OH3O

[

Reaction mechanism

H H O N N

NH 3

N

+

H H H H

O O V - V - O

NO(g)

O H O H V V O

O OH V O V O OH V O V H H O N N H H O N N

O H O H V V O

H 2 O

O V O V

1 / 2 O 2

O O V - V - O

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DeNOx reaction mechanism

1. Diffusion of the reactants to the catalyst surface 2. Adsorption of NH3 on an active site 3. Reaction of NH3 with NOx 4. Diffusion of products back to the flue gas 5. Reoxidation of vanadium site

NH3 NO NH3 NH3 NO H2O N2 O2 Catalyst pore Catalyst surface Laminar- gas film

1 2 3 4 5

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DeNOx technology General system layout

  • Ammonia storage
  • Ammonia evaporation
  • Ammonia injection
  • Flow stratification
  • Soot blowers
  • SCR reactor and catalyst
  • Control system

Boiler flue gas Dilution air Blower FT FT PC NOx inlet signal FV NH3 NH3 Evaporator NOx outlet signal Flue gas flow signal Cleaned gas SCR reactor

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Topsoe DNX catalyst characteristics

  • Corrugated honeycomb
  • Open geometry
  • Titania based and impregnated with vanadium and

tungsten

  • High strength – fibre reinforced
  • Very porous structure
  • High poisoning resistance
  • Low SO2 oxidation
  • Thermal shock resistant
  • Temperature range:

180°C – 555°C

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Channes size

 2.5-10.0 mm

Wall thickness

 0.4, 0.8 and 1.0 mm

Chemical compositions

 10 different to optimise activity/SO2 oxidation

DeNOx catalyst – product range

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Catalyst Modules

  • Modular Design
  • 0.25, 0.50, 0.75, 1.00 meter catalyst height
  • 2 x 4 cassette standard design
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SCR process - Reactor

NH3 NOx (flue gas)

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DNX catalyst features Easy loading

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Advantages of Topsoe DNX Catalyst & Technology Topsoe Operating Experience:

  • Gas flows up to 2.7 million

Nm 3/h.

  • SOx contents up to 5% (vol.).
  • Temperatures between 180

and 475°C.

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Performance Sheet

S.No. Parameter Outlet

1. NOx, ppm <25 2. NH3 slip, mg/Nm 3 @ 6% O2 dry <10 3. NH3 reagent consumption, Kg/hr Low 4. Pressure Drop, mmH20 (4 oC) 20

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Reference

T

  • psoe DeNOx

T echnology has

around ≈1200

references world wide in different sectors:

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Catalytic Filtration Solution Over View

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Oxidation

SCR Filtration

HT DNX Series HT CK Series

Combining competences Haldor Topsoe

Fabric Filters & Filter Bags

NOx Dioxins & Furans NH3 CO VOCs Dust/PM HC

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Technology

EnviroTexTM Catalytic filter bags

  • Each bag consist of three fabric layers

(bags) which individually are impregnated

  • High filtration efficiency
  • Filter bag up to 464 F (240 deg. C)
  • VOC, ammonia removal, and DeNOx at low

temperature

  • No poisoning of catalyst

Design T: 410-464 F (210-260 C) Dimension: app. 20-40 feet (6-12m) length

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Catalytic filter bag

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Catalytic Filter Bag

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Catalytic filter bag

Fibers Catalyst

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Technology

Design T: 410-752 F (210-400 C) Dimension: 1-3m length

TopFraxTM Catalytic ceramic filters

  • Each filter consist of a ceramic fiber based filter

impregnated with a catalyst in the filter wall (20 mm thick)

  • High filtration efficiency (<2 mg/Nm 3)
  • Up to 662 F (350 deg C) with present catalyst

(filter up to 900 deg. C)

  • DeNOx, ammonia and VOC removal.
  • No poisoning of catalyst
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NOx and NH3 removal (SCR)

Catalytic filter bag Particulate matter (dust)

N2 H2O N2 N2 H2O

Clean gas Off-gas

NO O2 O2 NO NO2

Gasflow

NH3 NH3 O2

4 NO + 4 NH3 + O2 -> 4 N2 + 6 H2O

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NOx and NH3 removal (SCR)

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Removal of VOC’s / Organic HAP

Catalytic filter bag Particulate matter (dust)

N2 H2O CO2 N2 H2O

Clean gas Off-gas

O2 O2 O2

Gasflow

VOC VOC O2 VOC CO2

CH2O + O2 -> CO2 + H2O VOC = Volatile Organic Compound: CO, Toluene, Benzene, Formaldehyde etc. HAP = Hazardous Air Pollutant

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Removal of VOC’s / Organic HAP

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Furan/dioxin removal

Catalytic filter bag Particulate matter (dust)

N2 H2O CO2 N2 H2O

Clean gas Off-gas

O2 O2 O2

Gasflow

Dioxin Dioxin O2 Furan Furan CO2

HCl

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CataFlexTM Catalytic filter bag principle

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TopFraxTM Ceramic filter principle

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Schematic illustration of the catalytic filter bag

  • 1. layer
  • 2. layer

Membrane

  • 3. layer

Catalyst Catalyst Catalyst

VOC NOx NH3 CO VOC NOx NH3 CO VOC NOx NH3 CO VOC NOx NH3 CO Dust Dust Dust Dust

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Application of catalytic filtration Technology

  • Cement kilns
  • Power plants
  • Waste incinerators
  • Chemical industry
  • Biomass
  • Glass plants
  • Metal production (sintering)
  • Roasting (Corn, cacao, cofee)
  • Carbon black

Etc… .

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Overview – Legislation within Cement Manufacturing

USA Germany China (Common) ¤ World (Financing) Pollutant NESHAP/NSPS BImSchV 17 GB30485-2013 World bank HCl 5 10 10 10 THC (TOC) 3.6 10* 10 10 SO2 94 50* 200 400 NOx 360 200 400 600 NH3

  • 30

10

  • Hg

0.005 0.03 0.05 0.05 Dust 1.8 10 30 30

mg/Nm 3 @ 10 vol. % O2 (dry)

* ) Exceptions for raw materials possible

¤) Cement plants co-processing waste in common regions. The key region limits are stricter.

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Catalytic Filtration Solutions

  • ----------------------------------------------------------------------------------conclusion
  • New cost efficient solution for removing gas emission along with particulate matter
  • Making the plants staying in compliance with even the stringent regulations
  • Saves up to 80% on CAPEX compared to existing solutions used today
  • Saves operational cost (OPEX) compared to existing solution used today
  • Saves foot print of the total installation compared to existing solution used today
  • Targeting Waste to Energy, Boilers, Cement Plants, Glass Plants
  • …and similar industries with a flue gas containing hazardous compounds and dust
  • Removal of (separately or combined at the same time):
  • NOx
  • HAP (hazardous air pollutants)
  • VOC (volatile organic compounds)
  • CO
  • Dioxin and Furans
  • NH3
  • Dust and particulate matter (PM)
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  • 48
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Sachin Panwar

Business Development Manager

sapa@topsoe.in

Questions?