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Energy Saving Denox - Catalysts: Ruedi Frey, Hitachi Zosen Inova, Zürich

This document discusses various applications of selective catalytic reduction (SCR) technology for reducing nitrogen oxide (NOx) emissions, including high-temperature SCR used downstream of electrostatic precipitators, tail-end SCR used downstream of flue gas treatment with reheating, and low-temperature SCR used downstream without permanent reheating. It provides examples of SCR installations in Switzerland, France, the Netherlands, and other countries. It also describes Hitachi Zosen Inova's Xerosorp+ compact SCR system used in a retrofit of the Hinwil, Switzerland waste incineration plant, highlighting features like periodic compartmental regeneration and integrated heat recovery.

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166 views30 pages

Energy Saving Denox - Catalysts: Ruedi Frey, Hitachi Zosen Inova, Zürich

This document discusses various applications of selective catalytic reduction (SCR) technology for reducing nitrogen oxide (NOx) emissions, including high-temperature SCR used downstream of electrostatic precipitators, tail-end SCR used downstream of flue gas treatment with reheating, and low-temperature SCR used downstream without permanent reheating. It provides examples of SCR installations in Switzerland, France, the Netherlands, and other countries. It also describes Hitachi Zosen Inova's Xerosorp+ compact SCR system used in a retrofit of the Hinwil, Switzerland waste incineration plant, highlighting features like periodic compartmental regeneration and integrated heat recovery.

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nay den
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© © All Rights Reserved
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Energy saving DeNOx - catalysts

Ruedi Frey, Hitachi Zosen Inova, Zrich

Content

Principles of SCR application


High SOx application
Preamble: Developpment of 4D-filter-technology
Low temperature application
Xerosorp+: compact and smart design
conclusion

Name of Presentation

Principal SCR DeNOx applications


High SOx SCR:

ESP
NH4OH

260

300
C

HP
steam
HX

NOx

upstream further FGT; no reheating


Economizer /
further FGT

Tail end SCR:

NH4OH
240C

downstream FGT; permanent reheating

NOx
Stack

From FGT

T = 260 300C

T = 230 250 (300) C

Gas/gas HX

Low temperature SCR:


Regen.
burner
From FGT

NH4OH
180C

NOx

downstream FGT; no permanent heating


Stack

T = 180 200C
(up to 320C for periodical regeneration)

High SOx SCR


Principle and main features
No reheating, works between 250
300C (boiler to be designed
accordingly); SCR followed by
economizer and further FGT
Dust pre-separation by 3 field
electrostatic precipitator
Soot blowers for periodical dust
removal
Typical pitch 6.3 mm (or plate
type modules)

From boiler /
dust separation
- ESP

Soot blowers
(periodical dust
removal)

NH4OH
260
300C

NOx

To economizer and
further FGC

High SOx SCR reference KVA Thun (CH)

Capacity: 100000 t/a (1 line)


Start-up year: 2004
Operator: AVAG Thun www.avag.ch
Main contractor: Von Roll Inova

High SOx SCR reference KVA Thun (CH)

SCR,
external Eco

Acidic ash washing


Effluent treatment

3-field
ESP

270

Tail end
fabric Filter
Wet
scrubber

170

60

Temperature profile [C]

120

High SOx SCR reference KVA Thun (CH)


Experiences since 2005:
A later (2007) installed water injection to the combustion chamber accelerated
pressure drop increase in a not acceptable manner
Therefore, causes has been investigated

High SOx SCR references

Conclusions:
3 main parameters have an impact on catalyst plugging: dust, SO2 and H2O
concentration in the flue gas
Thun: additional water injection was reduced or stopped when one of this
parameters exceeded a certain limit  fouling can be limited
Good working ESP (with at least 3 fields) is important, as well as continues
dust monitoring downstream ESP to detect a malfunction immediately
Honeycomb type modules easier to clean in case of then plate type
catalyst modules

Concept 4D-Filter

ic
B

ok
K
+
r

Von Rolls 4D-Filter

Filter candles
with catalytic
coating

Clean gas

Filter cake

Dry absorption

DeSulfurisation
NOx removal

DeNOx
Raw gas
Dust Removal

Dioxin reduction

DeDust

DeDioxination
dust / residues

Pilot plant 4D-Filter

location:

KEBAG Zuchwil,
boiler roof

Flue gas from:

upstream ESP L3
ca. 300 m3/h

Temperature:
190 250C adjustable
with electrical heating device
In operation:

1998 2001
approx. 20000 h

Crux of the matter: temperature gap

SCR efficient above 220C ; Hg-removal good below 190C


 compromise temperature = 180 200C
 Same temperature gap for process in 2 steps (dry sorption first,
followed by SCR)

Issy-les-Moulineaux (Paris)
Starting point January 2000:
SYCTOM (joint waste management authority of Paris) calls for a tender for a
totally new plant in Issy-les-Moulineaux, with special focus to a dry but efficient
flue gas treatment
requirements:

> no plume at stack


> low emissions
> no liquid effluent
460000 t/a waste throughput
2 Lines

Grundwasser

Issy-les-Moulineaux (Paris)

Concept Von Roll Inova:


Double filtration, dry process with sodium bicarbonate
SCR at 180C without permanent reheating
Regeneration- / anti-panache-burner allows heating up flue gas upstream
SCR to 320C
Additivinjection /
reactor

ESP

Fabric Filter

burner
SCR

Issy-les-Moulineaux (Paris)

Where is the stack ?

here !

Evreux - FR
Starting point 2002:
Call for tender with bivalent FGT : semidry with lime or dry with bicar; with
catalytically DeNOx
requirements:

> no plume at stack


> low emissions
> no liquid effluents

90000 t/a waste throughput


2 Lines

Evreux - FGT
Concept Von Roll Inova:
Circulating fluidized bed reactor with integrated residue recirculation
Suitable for hydrated lime (with water injection) or bicarbonate (dry)
SCR at 180C (permanent reheating in case of lime as additiv)
Regeneration- / anti-panache-burner allows heating up flue gas upstream
SCR to 320C)
fabric filter
CFB-reactor with
residue recirculation
SCR

Roosendaal - NL
Starting point 2006:
SITA asks for a plant with dry FGT: pre-separation of dust, dry absorption, SCR
2. Fabric filter was in discussion

290000 t/a waste throughput


2 Lines

Roosendaal - NL
Concept Von Roll Inova:
ESP, dry absorption with sodium bicarbonate (reactor / fabric filter)
SCR at 180C; regeneration-burner

Reaktor

E-Filter

GewebeFilter
SCR

Roosendaal NL SCR-Regeneration
Regeneration (every
1000 h)

Roosendaal NL SCR-Regeneration

Start NH4OH
controller  0
Heating up
NOx tends to
0

End phase
NOx
increases

End NH4OHcontroller
stabilising

References low temperature SCR

Evreux FR (2004)

Uppsala SE (2005)

Issanne FR (2007)

Roosendaal NL (2011)

Le Mans FR (2003)

Leudelange LUX (2010)

Nantes FR (2006)

Hinwil CH (2012)

Zistersdorf AT (2009)

KEZO Hinwil: Location, history

1970 1. incineration line


1991 Wet FGT with evaporation / NaCl production
(no permit for effluent discharge)
1996 SCR DeNOx

Zrich

2012 Retrofit FGT


200000 t/a waste throughput
3 Lines

Name of Presentation 23

KEZO Hinwil: Innovation has tradition

1996: SCR with heatpipe-HEX and


high pressure steam HEX

2005: dry extraction of bottom ash /


optimised metal recovery

2009: green house connected to


district heating

Name of Presentation 24

KEZO Hinwil: retrofit FGT


Starting point 2008:
High operation- and maintenance costs due to effluent evaporation
Own energy need relatively high (DeNOx, evaporation)
Need for retrofit (replacement or completely new FGT design) because of
evaporation plant and DeNOx HEX
Collecting flue after ESP shall equialize flue gas inhomogenity
 Search for alternative solutions, with main items
- Dry FGT with sodium bicarbonate (shortcut to wet scrubber /
evaporation)
- lowering SCR temperature
- Additional heat extraction, low pressure drop / own energy consumption

Name of Presentation 25

Lsungsvorschlag HZI: Kompakt und schnell


Concept Hitachi Zosen Inova:
Xerosorp - fabric filter with
integrated residue recirculation
Catalyst in compartments
SCR operated at 180C,
periodical regeneration
compartment by compartment
Flue gas recirculation for start-up
Compact design, situated beside
existing plant
 Short timetable for erection
and connection

Name of Presentation 26

Katalysator Xerosorp+ : normal operation and regeneration

3 compartments in
operation (180C)

compartment in
regeneration
(300C)

Gas burner

Status
March 2011: contract signed

October 2011:
Base plate
covered with
concrete

June/July 2012:
1. Flue gas cleaned

Name of Presentation 28

Technical Highlights

Integrated Recirculation of residues good bicar stoechiometry and low


emissions
Filter and catalyst in compartments, within the same steel structure, delivery in
pre-assembled and tested units high quality standard, quick mounting
Mini-burner for regeneration low propane consumption for periodic
regeneration; flue gas exit temperature only slightly increased
Super heat recovery with downstream water/gas HEX

Name of Presentation 29

Conclusion

HZI takes the next step towards highly optimised solutions in flue gas treatment
10 years after first application with dry FGT with sodium bicarbonate and low
temperature SCR (and continues improvements)
thanks to a cooperation with a client looking for good and innovative
solutions and bringing them forward
Even when R1-formula supposes use of steam for flue gas reheating as
beneficial:
dont waste your energy in flue gas treatment !

Name of Presentation 30

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