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The exhaust gas processing system using a pipe filter which we are now introducing
aims at processing floating mist and gases efficiently with a simple unit and with lower
maintenance and running costs.
2. Performance and Characteristics
Target exhaust gas:
Exhaust gases containing any type of mist except for strong alkali or hydrogen fluoride
Because the void ratio and the filtering area per filter is very large and the outer and
inner densities are diverse, all sizes of mist particles can be collected efficiently with
only a small pressure loss. Because of being made of glass, the filter is superior in
heat resistance and it does not swell nor change its shape.
The mist particles collected by the glass fiber layers are naturally coagulated to drop
and be discharged out through a drain. Even if the source gas includes insoluble
dust, those of particles diameter 1 micro-m or smaller flows with the collected fluid.
(Dust particles of 1 micro-m or larger should be processed in advance.) Such a self-
cleaning function allows stable performance for a prolonged period of time without
the need for maintenance, as well as having a simple structure; it can be installed
cheaper, it is compact, and operation and management are very easy.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
4. Applicable Gases
Mist and exhaust gases produced by various chemical devices and production
processes.
5. Example of Implementation
Treated gases:
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
In Japan, municipal solid waste (MSW) incineration has outweighed others in the
intermediate treatment system because of its capabilities to sanitate and reduce
volume of waste. However, environmental pollutants such as dust, NOx, SOx, HCl,
dioxins and heavy metals are included in the flue gas from MSW incinerators. As
awareness to environmental preservation, high efficient flue gas treatment system is
being required to reduce these pollutants. In this term, advanced flue gas treatment
system using the bag house filter, and catalytic denitrification tower etc. is shown.
2. Constitution
Fig.1 Schematic flow diagram of flue gas system
3. Characteristic
(1) Dioxins can be removed at high efficiency by the bag house filter followed by the
catalytic denitrification tower or the activated coke packed tower.
(2) Dioxins and NOx can be removed simultaneously by the catalytic denitrification
tower.
(3) In order to improve dioxins and Hg removal efficiency, the additives such as
activated carbon is fed.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
(4) Dust, Heavy metals and acid gas such as HCl, HF, can be removed at high
efficiency by the bag house filter.
(5) The catalytic denitrification can be conducted effectively even at low temperature
using low temperature active catalyst which was developed.
4. Application field
Flue gas treatment of MSW and industrial waste incineration and melting furnace of
MSW incinerator ash.
5. Operation data and effect
Experimental data of flue gas treatment from existing fluidized bed incinerator of
MSW are shown below.
(1) Dioxins: <0.1 ngTEQ/m3N (Fig.3)
(the activated coke packed tower/denitrification catalyzer outlet)
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Fig.4 Example of measured NOx at inlet and outlet of catalytic denitrification tower
(Catalyst temperature 170 deg.C, SV 1600h-1, NH3/NO.1.0)
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
3. FEATURES
(1) Acid gas high removal efficiency is attained thanks to combination of multistage
spray tower and packed tower.
(2) White smoke emitted from the stack is reduced greatly by dehumidification and
re-heating of the treated gas.
(3) Stable operation is ensured by automatic control of pH and salt concentration in
the waste liquid.
4. APPLICATIONS
KAWASAKI has abundant experiences in treatments of combustion exhaust gas
emitted from municipal solid waste containing much HCl as well as SOx.
1) Gas volume : Free
2) Gas temperature : 150 - 300 deg.C
3) Acid gas removal rate : HCl Less than 15 ppm
SO2 Less than 10 ppm
Fig.1. Actual data of HCl removing performance of wet-type noxious gas removing
equipment
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
<Fumaks Process>
<Rhodacs Process>
By scrubbing crude gas containing hydrogen cyanide with sulfur suspended alkalic
solution, hydrogen cyanide is removed in the form of thiocyanate which is non-toxic.
2. Schematic Diagram
An example of the flow sheet of Fumaks, Rhodacs and Compacs processes
3. Advantages
<Fumaks Process>
- Desulfurization efficiency can be adjusted in the design close to 100% according to
the customer's requirement. Stable efficiency can be maintained.
- Low cost of chemicals for desulfurization
- The absorption liquid can be circulated (recycled) under ambient temperature
without pressurization
- Efficient regeneration by premix nozzles
- Small land space and low installation cost
- Sulfur recovery efficiency is as high as 70 to 80%
<Rhodacs Process>
- Decyanization efficiency can be adjusted in the design up to 100% according to the
customer's requirement.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
- When H2S, NH3 and HCN are contained simultaneously in the process gas, toxic
substances can be removed through chemical reactions of these compounds, thus
improving the process economy.
- Compact system
- Easy operation and maintenance
4. Treatment Capacity
The process is applied for plants with gas treatment capacity of 1,200 to
200,000Nm3/h.
5. Applications
Purification for coal gas or oil gas
6. Installations
Since 1960, there have been
23 installations with Fumaks Process,
8 installations with Rhodacs Process,
and 11 installations with combined Fumaks-Rhodacs Processes.
since 1960.
7. Treatment of the waste water from these Processes
There is a waste water burning process which can turn solid sulfur or sulfur
compounds into useful products. (See Page about "Compacs Process")
Kobe Steel, Ltd. has obtained technical assistance from Union Cabide Corporation in
designing and constructing the plants shown in the Reference section.
2. Features
1) A very effective activator is used to lower the equilibrium partial pressure of acid
gases and accelerate the absorption rate.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
3. Process Flow
The absorption and regeneration of acid gases in the Benfield Process are based on
the following reactions:
K2CO3 + CO2 + H2O = 2KHCO3 (1)
K2CO3 + H2S = KHS + KHCO3 (2)
In the HiPure Process, the reactions described below are added.
2R2NH + CO2 + H2O = (R2NH2)2CO3 (3)
(R2NH2)2CO3 + CO2 + H2O = 2R2NH2HCO3 (4)
2R2NH + H2S = (R2NH2)2S (5)
(R2NH2)2S + H2S = 2R2NH2HS (6)
The absorption and regeneration of acid gases are conducted in a similar way to that
of the conventional amine or carbonate processes. The gas to be treated is fed to the
bottom of the absorber and flows countercurrent to the absorbing liquid supplied at
the top of the absorber.
Acid gases are then absorbed by the absorbing liquid. The liquid that has absorbed
the acid gases is preheated and then supplied to the top of the regenerator where the
acid gases are stripped by steam for the regeneration of the liquid. The regenerated
liquid is precooled and recirculated to the absorber.
4. Benfield Process
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Kobe Steel, Ltd. first obtained technical assistance from the British Gas Corporation
in 1964. Since then we have designed and constructed the plants shown in the
Reference section.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
2. Features
1) This process is applicable to any gas, such as coke oven gas, natural gas, oil
refinery, gas, reformed gas, coal gas, etc.
2) The hydrogen sulfide content in the treated tail gas can be reduced to less than
0.1 ppm at atmospheric and higher pressures.
3) Sulfur is recovered with a high purity of more than 99.5 wt.%
4) Hydrogen sulfide is selectively removed from gas streams containing a high
concentration CO2 with high efficiency.
5) Simple operation and energy savings can be achieved as the absorption and
regeneration are performed at moderate temperature (30 - 40 deg.C) .
6) The chemicals used in the process are stable, nontoxic and easily treated.
7) Several effluent treatment systems have been established. So there is no problem
of secondary pollution due to the effluent.
8) The absorbing solution is weakly alkaline (pH 8.5 - 9.0) and noncorrosive.
3. Reaction Mechanism
The absorption and regeneration are based on the socalled "Redox reaction" that
causes the catalyst effects of anthraquinone disulfonic acid (in short, ADA)and
vanadate in a weakly alkaline solution.
2H2S + 2Na2CO3 -> 2NaHS + 2NaHCO3 (1)
2NaHS + 4NaVO3 + 4NaHCO3 -> 2S + Na2V4O2 + 4Na2CO3 + 3H2O (2)
Na2V4O2 + 2Na2ADA + 2Na2CO3 + 3H2O ->
4NaVO3 + 2Na2ADA(Redured) + 2NaHCO3 (3)
2Na2ADA (Reduced) + O2 -> 2Na2ADA + 2H2O (4)
4. Process Flow
The gas to be treated flows countercurrent to the absorbing solution in the absorber
and H2S is removed by the reaction with the absorbing solution. The packings used
in the absorber are usually splash-type plates designed in a specific manner. The
absorbing solution is delayed at the bottom of the absorber and hydrogen sulfide in
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
the solution is converted to elemental sulfur as a result of the reaction. Then the
solution is sent to the oxidizer, where a supply of air is received to regenerate the
solution completely and to float elemental sulfur in the slurry. The froth of the sulfur
slurry is concentrated by a filter or a centrifuge to form sulfur cake, which is reslurried
with water and heated to recover molten sulfur of high purity from the sulfur
separator.
On the other hand, the solution regenerated in the oxidizer is sent to the balance pit
and then pumped up to the absorber.
5. Stretford Process
Flow Diagram
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
CASE 2
3. FEATURES
(1) Because this is of completely dry type and uses no water, no white smoke is
generated and a trouble resulting from calcium ion accumulation does not occur.
(2) When installed at downstream of the dust collecting device, reaction products can
be separated from fly ashes ensuring remarkable utilization.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
4. APPLICATIONS
1) Gas volume Free
2) Gas temperature 200 - 300 deg.C
3) Acid gas removal rate HCl Less than 50 ppm
(In case of MSW Incineration Plant)
SO2 Less than 10 ppm
(In case of MSW Incineration Plant)
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Fig.1 shows the flowchart of the wet type hydrogen chloride and sulfur oxides
removal system.
Fig.1 Wet type hydrogen chloride and sulfur oxides removal system
3. Characteristics
The treatment allows for removing 95 to 98% of hydrogen chloride and 85 to 95% of
sulfur oxides. Water treatment process and plume preventive equipment are
necessary. The mercury elimination efficiency is 80 to 90%.
4. Capacity
This system has no limit on the treated gas volume.
5. Sphere of application
This system can be applied to any furnace exhaust gas, for example, one for
Municipal Solid Waste (MSW) incineration.
6. Actual results
Takuma has installed 30 wet type hydrogen chloride and sulfur oxides removal
systems in MSW incineration furnaces in Japan.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
In this system, hydrated lime (calcium hydroxide) slurry is injected into a quenching
reactor to reduce the gas temperature and to neutralize the acid gas contained in the
exhaust gas. Hydrated lime powder is injected into a dry venturi to enhance the
pollutant removal effect. A baghouse (fabric filter) is designed to allow a formation of
a thick dust cake layer on its surface. When the exhaust gas passes through the
baghouse, the unreacted hydrated lime contained in the cake layer contacts and
reacts with the acid gas in the exhaust gas, thereby improving removal effect.
Fig.1 shows the flowchart of the semi-dry type hydrogen chloride and sulfur oxides
removal system.
Fig.1 Semi-dry type hydrogen chloride and sulfur oxides removal system
3. Characteristics
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
The treatment allows for removing 90 to 98% of hydrogen chloride and 80 to 95% of
sulfur oxides. Water treatment process and plume preventive equipment are not
required. The mercury elimination efficiency is 50 to 70%.
The removing performance of the semi-dry type is largely dependent on the gas
temperature at the baghouse; the gas temperature should be controlled very
precisely by spraying hydrated lime slurry in the quenching reactor. At lower gas
temperatures, larger amounts of hydrogen chloride and sulfur oxides are removed.
5. Capacity
This system has no limit on the treated gas volume.
6. Sphere of application
This system can be applied to any furnace exhaust gas, for example, one for
Municipal Solid Waste (MSW) incineration.
7. Actual results
Takuma has installed 10 semi-dry type hydrogen chloride and sulfur oxides removal
systems in MSW incineration furnaces in Japan.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Fig.1 shows the flowchart of the dry type hydrogen chloride and sulfur oxides removal
system.
Fig.1 Dry type hydrogen chloride and sulfur oxides removal system
3. Characteristics
The treatment allows for removing 80 to 95% of hydrogen chloride and 55 to 75% of
sulfur oxides. Water treatment process and plume preventive equipment are not
required. The mercury elimination efficiency is 50 to 70%.
The removing performance of the dry type is largely dependent on the gas
temperature at the baghouse; the gas temperature should be controlled very
precisely by spraying water at an upstream quenching cooler. At lower gas
temperatures, large amounts of hydrogen chloride and sulfur oxides are removed.
4. Capacity
This system has no limit on the treated gas volume.
5. Sphere of application
This system can be applied to any furnace exhaust gas, for example, one for
Municipal Solid Waste (MSW) incineration.
5. Actual results
Takuma has installed 15 dry type hydrogen chloride and sulfur oxides removal
systems in MSW incineration furnaces in Japan.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Catalytic Incinerator
1. Outline
This equipment catches malodorous gases with the platinum catalyst and
decomposes them by oxidation to harmless and odorless carbonic acid gas and
water. Compared with the direct combustion type, this equipment is capable of
treating malodorous gases at low temperature, so running cost is low. In case
concentration of malodorous substances is low in particular, it is advisable to install
Honeycomb Type Deodorization Equipment as a pre-treatment equipment to save
energy greatly.
2. Structure of the equipment
- Treating gas containing malodorous substances are pre-heated while it is passing
through the heat exchanger.
- Treating gas is heated to the predesigned temperature by the auxiliary heater
(generally to 300 deg.C ). Electricity, city gas, LPG, kerosene oil, etc. can be selected
as heat source.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
- When heated treating gas passes through the catalyst-bed, malodorous substances
contained are decomposed by oxidation as they contact the catalyst.
- Purified gas is exhausted after passing through the heat exchanger where heat is
exchanged between purified gas and treating gas.
In combination with a steam heater:
In case electricity is used as heat source for the auxiliary heater, it is advisable to use
a steam heater together with it to reduce electric consumption greatly, which reduces
running cost.
3. Features
- Low running cost: Compared with the direct combustion system, this equipment is
capable of treating malodorous substance at low temperature, so fuel costs can be
reduced by under (1/3).
- No secondary air pollution is ensured.
- Low boiling organic solvents and wider ranges of malodorous substances can be
purified.
- Power source for auxiliary gas burner can be selected widely. Since the mixed type
gas burner is used, city gas, LPG, butane gas, etc. can be used as heat source with
the simple adjustment of the gas burner. Electric system is standardized for smaller
units.
4. Applied fields
Chemical industries, painting, printing, rubber and casting factories
5. Installation example of system
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
HITACHI ZOSEN has been making every effort to research, develop and improve
flue gas cleaning systems to meet clean air standards which are getting progressively
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
more and more strict and severe in every countries in the world. This document
briefly introduces DRY TYPE FLUE GAS TREATMENT SYSTEM which is one of
typical types of flue gas cleaning system.
2. PROCESS DESCRIPTION
This system consists of the following equipment as shown on fig.1;
Fig.1 is simplified flow chart of this DRY TYPE FLUE GAS TREATMENT SYSTEM
(Bag filter system). Flue gas from a refuse incinerator is fed to Evaporative Type
Cooler, in which the flue gas temperature is regulated by means of evaporation of
injected water. The flue gas temperature at the inlet of Bag Filter is controlled to be
appropriate for the reaction, which makes the removal of gaseous pollutants efficient
and prevents the filter cloth from clogging caused by melting of reaction products
(salt) such as CaCl2 and suffering heat damage.
After being temperature-conditioned, the flue gas is mixed with fine-grained Ca(OH)2
and supplemental agent which are supplied into the flue gas duct, where powdered
Ca(OH)2 reacts with gaseous pollutants such as SO2, SO3, HCl and HF (if any). In
simple terms, the following reactions take place;
2SO2 + 2Ca(OH)2 -> 2CaSO3.(1/2)H2O + H2O (1)
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The filtrate cake is periodically removed from the filter cloth by means of pulse jet of
compressed air injected into clean side of the bag house with a lance(on-line
cleaning).
The relation between the flue gas temperature controlled, Equivalent of Ca(OH)2 to
HCl/SOx and the gaseous pollutants removal efficiency is shown on fig.2.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
3. SYSTEM FEATURES
Nowadays this system has high performance of noxious gases removal at the same
as with the Wet Type Process on constant research and much experience on this
system (We at HITACHI ZOSEN has 44 plants of actual experience as of April,
1998).
This DRY TYPE FLUE GAS TREATMENT SYSTEM has main features as follows;
This document briefly introduces WET TYPE FLUE GAS TREATMENT SYSTEM
which is one of typical types of flue gas cleaning system.
2. PROCESS DESCRIPTION
This system consists of the following equipment as typically shown on fig.1;
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Flue gas from a refuse incinerator is fed to Scrubber in which the flue gas is cooled to
saturation temperature and simultaneously contained gaseous noxious pollutants are
absorbed (removed) by contact with circulating water. The noxious pollutants
absorbed in the circulating water, reacts with caustic soda injected as follows;
SO2 + 2NaOH -> Na2SO3 + H2O (1)
SO3 + 2NaOH -> Na2SO4 + H2O (2)
HCl + NaOH -> NaCl + H2O (3)
If HF is present in the flue gas,
HF + NaOH -> NaF + H2O (4)
The flue gas from the lower part (Cooling Part) rises to the upper part
(Dehumidification Part) of the Scrubber, where the gas is first distributed to the
packed bed and contact with circulating water efficiently for further absorption of
remained gaseous pollutants. Simultaneously the flue gas is supercooled
(dehumidified), because the circulating water is forced to be cooled through Cooling
Tower, and it effects prevention of white plume from the Stack.
The flue gas leaving this Scrubber is fed into Air/Gas Mixer where the flue gas is
mixed with heated air, thus the flue gas is heated up and its water content is reduced
to be under less than saturation point. After that the flue gas is fed into Gas Reheater
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
As is mentioned above, acid gas such as HCl and SOx contained in the flue gas is
neutralized with caustic soda injected into the circulating water, and as a result it
generate salt such as NaCl and Na2SO4. If this salt was not at all discharged, it is
possible to cause clogging of the flue gas entrance of the Scrubber by its drying-up
(Crystallising). Therefore, a part of the scrubbing water is withdrawn from the
Scrubber sump with adjusting concentration of salt-compounds (TDS) not more than
10% and is sent to Wastewater Treatment Plant. The Scrubber sump bottom is
withdrawn periodically and pumped up to Hydrocyclone in order to remove solids or
foreign materials which might cause clogging of Spray Nozzles for the circulating
water.
3. SYSTEM FEATURES
Flue gas introduced into Scrubber is very corrosive due to contained various acid
gases, and has a high temperature, therefore it is necessary for the Scrubber to be
specially considered to be protected from troubles such as its internal's corrosion and
burning out. The inside of this Scrubber is made completely corrosion-proof and
thermal resistant by employing firebricks, resin and resin lined material. And further
other assistant equipment is designed for keeping not only of its performance, but
also its stable operation, on our much experience on this system (We at HITACHI
ZONES has 29 plants of actual experience as of April, 1998). Thus this our WET
TYPE FLUE GAS TREATMENT SYSTEM has main features as follows:
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2. PROCESS DESCRIPTION
This process consists of the following units;
Flue gas is fed to the top of Dedusting Column from a refuse incinerator, where the
flue gas is quickly cooled down and comparatively large particles of dust and
gaseous pollutants such as HCl and HF are removed by contact with circulating
water sprayed by LAB-G nozzles. Effluent from the bottom of this Dedusting Column
is circulated to the top of this Column by a water circulation pump. A part of
circulating water is withdrawn and is fed back after sludge removing via Hydrocyclone
and Thickener, and the wastewater contains the sludge is sent to Wastewater
Treatment System. This circulating water is injected with hydrated lime milk as an
absorbent and thus its pH value is controlled to be 1.5 - 2.5.
From the Dedusting Column, the flue gas is introduced to Venturi-type Dust Collector.
In this equipment, small particles of dust and water mist which is unable to be
removed in previous dedusting, are removed. At both inlet and outlet of this Venturi-
type Dust Collector, LAB-F nozzle is equipped which were developed by LAB.S.A.
The dust is covered by condensate through adiabatic expansion and collected by
sprayed water which is circulated via Circulation Tanks installed at inlet and outlet of
this Venturi-type Dust Collector respectively.
From the Venturi-type Dust Collector, the flue gas is fed to lower part of Absorber
where gaseous sulphur oxides are removed by contact with circulating water sprayed
through LAB-G nozzles. And here the gas can be dehumidified simultaneously, if the
circulating water is cooled through a cooling tower. It is effective to prevent white
plume exhausting from the Stack.
Flue gas saturated with water from the Absorber is introduced to the following
Electrofiltering module via Mist separator where entrained mist is removed. The
Electrofiltering module is one of venturi and it removes very small particles of micron
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size(organic and inorganic chlorine compounds, heavy metals, etc.) which are
contained in the flue gas. The small particles are collected by the filtered water film
by means of electromagnetism.
Hydrated lime is supplied in powdered form to Lime Silo by lorries. This hydrated lime
is fed to a desolving tank where it is adjusted as slurry of concentration of approx. 5 -
10%, and after that it is injected into circulating water of the Dedusting Column.
Further caustic soda of approx. 10% concentration is injected into circulating water of
the Absorber.
3. SYSTEM FEATURES
This process has the following advantages;
This process has two functions, that is, dust collection and absorption of gaseous
pollutants such as HCl, SOx, HF. This process is compact and simple compared with
one which treats functions separately.
LAB-G nozzle developed by LAB. S. A. has an original structure which is suitable for
a high density slurry with less blockage, erosion and damage.
This process uses hydrated lime or limestone as an absorbent. The chemical cost is
very low, approximately one third that of the conventional process, which uses
caustic soda.
This process effectively collects small particulates of micron size including organic or
inorganic chlorine compounds and heavy metals in the last unit, i.e., Electrofiltering
modules.
This process does not discharge any metals in the effluent and so it will be suitable
for the stricter effluent limits of the near future.
We are very glad if this EDV TYPE FLUE GAS TREATMENT SYSTEM would be of
service for worldwide clean air protection.
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2. Basic System
The exhaust-gas containing organic compounds is sucked into the heat exchanger
for preheating, and further heated in the gas heater before entering into the reactor.
After the exhaust-gas is decomposed and purified by the catalyst in the reactor,
treated gas is recycled into the heat exchanger to recover the reaction heat and
finally discharged from the stack into the atmosphere.
Depending on the contents and other conditions of exhaust-gas and the design of
heat exchanger, the system provides an energy-saving operation which decreases or
does not require auxiliary fuels.
3. Excellent Features of Catalytic Incineration System for Exhaust-Gas
Treatment
Among NIPPON SHOKUBAI's waste gas control systems, the catalytic incineration
system employing catalyst of NIPPON SHOKUBAI's own development provides
complete oxidation of pollutants and odorous substances at low temperatures
converting them harmless and odorless.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
This device removes wide range of these harmful substances with high efficiency.
2. Process outline
The exhaust gas from the municipal solid waste incinerator is cooled to a
temperature of 180 to 200 deg. C by the gas cooler, and then enters the mixing
chamber located at the inlet of the bag filter.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Filtration agency and hydrated lime transported by air from those silos are injected
into the mixing chamber. When mixed with the exhaust gas, the hydrated lime reacts
with hydrogen chloride and sulphur oxides, forming solid matter, which is collected by
the bag filter.
The surface of the bag filter is also coated with filtration agency and hydrated lime,
and this coating effectively collects dust and heavy metal particles.
3. Process features
1) The device uses dry-type processing which does not affect the exhaust gas
temperature directly. Therefore, no corrosion or dust adhesion trouble occurs in the
equipment.
2) The filtering effect of the filtration agency and hydrated lime prevents clogging of
the filter cloth, providing stable plant operation without an increase in the filtering
pressure loss.
3) The filtering effect of the filtration agency and hydrated lime removes dust and
microscopic heavy metal particles effectively.
4. Processing capacity
1) Gas volume : no limitation
2) Gas temperature :160 to 220 deg.C
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
5. Application range
This device is designed mainly for the treatment of exhaust gas generated by the
incineration of municipal solid waste. However, it can also be used to process gases
produced from various types of furnace.
6. Performance measurement result
Table 1 shows an example of performance measurement.
2. Process Flow
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Since slaked lime is injected in the powder form, the system simple.
According to the flow described above, HCl can be removed as low as 40 ppm (in
terms of 12% O2), but when removing HCl to less than 40 to 25 ppm (in terms of 12%
O2), reaction assistant agent has to be injected together with slaked lime as shown in
the figure below:
3. Characteristics
(1) Equipment is simplified.
(2) Lowering the inlet flue gas temperature of bag filter permits higher removal
efficiency. However, when the temperature drops below 140 degrees C, low
temperature corrosion is generated in the ducts and casing. Therefore, the system
should be operated at temperatures above 150 degrees C to prevent the corrosion.
(3) The reaction assistant agent which would be injected in order to raise the reaction
efficiency, is an extremely porous particles so as to promote the depositing of
reaction products on the bug filter cloth dust layers. This arrangement also promotes
better permeability and it also aids in increasing the chances of contacting unreacted
slaked lime contained in the reaction products.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Relation between reaction temperature, Ca(OH)2 ratio and HCl removal efficiency
4. Results
Slaked lime is dissolved in water, and the slurry is refined with an atomizer for
injecting into flue gas. HCl and SOx contained in the flue gas are dissolved in droplets
containing slaked lime, reacts with slaked lime in the droplet, forms calcium chloride
(CaCl2), and stabilizes as solid salt. In the next instance, solid salt is completely dried
and formed into a spherical porous reaction products. The unreacted slaked lime
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
proceeds to slowly react with HCl and SOx contained into the flue gas. This reaction
occurs at bag filters.
The reaction process is shown in the figure below. Electronic microscopic photos of
reaction products are also shown below.
Reaction Process
2. Process Flow
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Slaked lime is atomized into flue gas by dissolving it in water and forming a slurry.
3. Characteristics
(1) Since the system uses low cost slake lime and high reaction efficiency, the
operating cost is low.
(2) Since secondary reaction is present by the use of bag house, a very high
removal efficiency is obtained. This is made possible by the porous particles of
reaction products captured at the bag filter. As the flue gas slowly passes through the
reaction product particles and the dust layers on the bag filter cloth, the chances of
unreacted slake lime reacting with HCl and SOx are increased.
4. Removal Efficiency
HCl removal efficiency
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Example of measurement
ABB pioneered the Filsorption technology and has now more than 15 years
comprehensive operating experience from extremely tough and demanding
applications. ABB has also developed the technique of feeding, conveying, collecting
and handling the Filsorption product to an impressive level of reliability.
With plants in commercial operation for more than one decade, ABB has gained
extensive experience from installing Filsorption Systems. Over 90 fabric filter
installations in Waste to Energy plants clean safely and effectively more than
11,000,000 m3 of flue gas every hour.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
The filter bags are cleaned by means of compressed air pulses which are directed
down through the bag openings. The compressed air expands the bag with a
stepped acceleration so that a fraction of the dust on the outside of the bag is
detached in a carefully controlled manner.
3. The technology
Activated coke or carbon with its high surface area is known to be effective in
collecting high molecular weight organic and mercury compounds. In the Filsorption
System a mixture of lime and activated coke or carbon is carefully distributed in the
gas stream by means of ABB compact reactor. The even distribution over the filter
area provides extensive contact between gas and sorbent, which is a prerequisite for
efficient cleaning. The lime enables the removal of acidic gases such as HCl, SO2
and SO3 in addition to the removal of mercury and organics by the coke/carbon.
The excellent collection characteristics of the fabric filter ensures extremely low
particulate emission levels.
The end product from the Filsorption System is normally fired in the waste furnace
where the lime acts as an absorbent contributing to a pre-separation of acidic gases
from the flue gas. Other methods are glassification or for neutralization of waste
water.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
The Filsorption system - reactor and filter - is designed with vertical or very steep
walls in the ducts and hoppers, making the dust discharge very effective.
Consequently all problems with dust deposits and sticking dust are eliminated.
4. Performance
By using the ABB Fabric Filter as a fixed bed absorption reactor the total particulate
emission is kept extremely low. This also allows the use of a fine-grained coke or
carbon while still maintaining a very low dust emission. The fine-grained coke or
carbon creates a very large contact area with excellent absorption for a given amount
of coke or carbon.
The ABB Fabric Filter offers an optimal collection capacity of sob-micron particles
thereby ensuring very low emission levels of heavy metals.
The even distribution of sorbent over the bag surface is an inherent feature of the
ABB design - a small deficit of sorbent anywhere on the surface will decrease local
flow resistance. This in turn leads to increased gas flow and due to the continuous
feed of sorbent, to immediate local cake repair. In this respect, the system is self-
balancing and automatically assures optimum sorbent/dust cake contact with the flue
gases.
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
3. System Flow
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Source: Global Environment Centre Foundation (GEC) - Ministry of the Environment of Japan - Website: http://gec.jp/
Quench tower
The Quench tower is designed and engineered for cooling high temperature exhaust
gases from incinerator, melting furnace, drying furnace, etc.
Exhaust gas from high temperature sources is cooled down with water vapor to the
saturation temperature of the gas by Quench tower. The Quench tower is used as a
pre-cooler for scrubbers, electoststic precipitators, etc.
Technical Information
Specification :
The Quench including spray headers and spray nozzles are made of corrosion
resistant materials, such as lining carbon steel, type 316L stainless steel, Hastily-C.
Both horizontal flow type and vertical flow type are available.
Advantages :
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