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

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 Solution Range • Catalytic Process Fundamental Steps • Topsoe Environmental solution. • Catalytic Filtration technology • Conclusion 2

Why Clean the Flue Gas? 3

Major Contributing Factors For Air Pollution 4

Daily cycle of pollutant concentration 5

Why VOCs, NOx ,SOx, PM are threat? • Forms ground level ozone (or smog) • Triggers asthma attacks and cancer • Contributes to acid rains 6

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.

Headquartered in Denmark, our 2,800 employees work with customers all over the globe Locations: Bahrain Beijing Buenos Aires Cape Town S H S E P E S Copenhagen Edmonton S P Houston E J oinville S P Kuala Lumpur S S E Los Angeles Moscow New Delhi S Rio de J aneiro Tianjin Headquarters H S Production P P S S Engineering E Sales & Service S 8

We provide a full range of products and services for a broad range of business Chemical Processing Hydroprocessing Emissions Management Ammonia Syngas Methanol Hydrogen SNG Naphtha Sulfuric acid Kerosene Sulfur removal Dimethyl ether Diesel NOx & CO removal Formaldehyde VGO VOC abatement Gasoline synthesis Resid Particulate filtration Process design, + High-performance + Proprietary + Business & Engineering, & licensing catalysts equipment technical services 9

Catalytic Process- Fundamental steps 1. Step 2. Step 3. Step 4. Step 5. Step Desorption of Gas phase transport and Adsorption of Surface Gas phase transport and products pore diffusion of educts educts reaction pore diffusion of products Reactant Products + + 10

Haldor Topsoe Solution For Environment Protection T echnology to transform sulfur pollutants into sulfuric acid Catalysts to clean the T echnologiyto remove vehicle exhaust nitrogen oxides T echnology to treat volatile organic compounds 11

Wet gas Sulfuric Acid A process for cleaning sulfur containing streams under production of concentrated sulfuric acid WSA Lean H 2 S gas Cleaned gas Rich H 2 S gas SRU tail gas HP Steam SWS gas SO 2 SO 3 Spent H 2 SO 4 H 2 SO 4 12

WSA process lay-out, H 2 S gas Reaction: H 2 SO 4 (g) → H 2 SO 4 (liq) Superheated steam Stack gas Blower Combustion air SO 2 Converter Blower BFW Steam Air Drum Interbed cooler WSA Interbed Condenser H 2 S gas cooler WHB Gas Combustor cooler Reaction: Acid cooler H 2 S + 1½O 2 → SO 2 + H 2 O CW Reaction: Reaction: Product acid SO 2 + ½O 2 → SO 3 SO 3 + H 2 O → H 2 SO 4 (g) 13

Topsoe Vanadium SCR for Indian automotive market • Very good low temperature conversion • Proprietary substrate, no dependancy on substrate • Full-body , unlike coated SCR manufacturers • Best in class dynamic response to transient • Local engine test and production conditions planned • Best in class sulfur tolerance, due to high • Mechanical durability, simple canning 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 14

Catalytic combustion process General VOC + O 2 = CO 2 + H 2 O 100 90 80 70 Conversion (%) 60 50 40 Carbon monoxide Methanol 30 Toluene 20 Chlorobenzene n-Hexane 10 Ammonia 0 0 50 100 150 200 250 300 350 400 450 Temperature ( o C) 15

Oxidation catalyst portfolio > 500 references Type Application CK- Cu-Mn Hydrocarbons, hydrocarbons with 302/322 oxygen and nitrogen. Silicon and bromine resistant CKM-2x CKM- 3324 CK-304 Pd Aromatics, CO, hydrogen, ammonia, short-chained alkanes CKM-3x, DNOC CK-305 Cr Halogenated hydrocarbons CK-395 Mn CK-306 Cr-Pd Halogenated hydrocarbons, CO CK-307 Pt All hydrocarbons, CO, sulphur compounds (<200 ppm) CK-428 Cu-Mn Sulphur compounds (>200 ppm), Pt ammonia 16

SCR DeNOx Technology 17

Chemical Reaction • 6 NO + 4 NH 3 → 5 N 2 + 6 H 2 O • 6 NO 2 + 8 NH 3 → 7 N 2 + 12 H 2 O O 2 makes the reaction faster Me=Vanadium or Tungsten Mechanism: • Adsorptions mechanism • Elay-Rideal mechanism • Langmuir-Hinshelwood mechanism 18

Reaction mechanism O OH (1) NH 3 + V 5+ -OH ↔ V-ONH 4 NH 3 H H V + V N O NO(g) H (2) V-ONH 4 + V=O ↔ V-ONH 3 -V 4+ -OH O H H N N O O OH → N 2 + H ONH 3 -V 4+ 4+ -OH O + V 5+ 5+ -OH (3) NO + V NO + V-ONH + H 2 O + V OH H V - V - + V 4+ + V 4+ -OH OH O H O O H (4) 2V 4+ -OH ↔ H 2 O + V 3+ + V=O V V (5) O 2 + 2V 3+ → 2V=O O (6) H 2 O + V 5+ -OH ↔ V 5+ -OH 3 O [ O H H N N O N N H H OH O V V O O O O H O 1 / 2 O 2 O H H 2 O V V V - V - V V O O O 19

DeNOx reaction mechanism 1. Diffusion of the reactants to the catalyst surface 2. Adsorption of NH 3 on an active site 3. Reaction of NH 3 with NOx 4. Diffusion of products back to the flue gas 5. Reoxidation of vanadium site 5 NH 3 NO H 2 O N 2 O 2 4 Laminar- gas film 1 3 Catalyst NH 3 surface NH 3 NO 2 Catalyst pore 20

DeNOx technology General system layout • Ammonia storage • Ammonia evaporation • Ammonia injection • Flow stratification Boiler flue gas • Soot blowers NOx inlet FT SCR • SCR reactor and catalyst signal reactor Flue gas flow signal • Control system PC FT FV NH 3 NH 3 Evaporator Dilution air Cleaned gas NOx outlet Blower signal 21

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 SO 2 oxidation • Thermal shock resistant • Temperature range: 180°C – 555°C 22

DeNOx catalyst – product range Channes size  2.5-10.0 mm Wall thickness  0.4, 0.8 and 1.0 mm Chemical compositions  10 different to optimise activity/SO 2 oxidation 23

Catalyst Modules • Modular Design • 0.25, 0.50, 0.75, 1.00 meter catalyst height • 2 x 4 cassette standard design 24

SCR process - Reactor NO x (flue gas) NH 3 25

DNX catalyst features Easy loading 26

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. 27

Performance Sheet S.No. Parameter Outlet 1. NOx, ppm <25 NH3 slip, mg/Nm 3 @ 6% O2 dry 2. <10 3. NH3 reagent consumption, Kg/hr Low Pressure Drop, mmH20 (4 o C) 4. 20 28

Reference T opsoe DeNOx T echnology has around ≈1200 references world wide in different sectors : 29

Catalytic Filtration Solution Over View 30

Combining competences Haldor Topsoe NH 3 NOx SCR HT DNX Series Dioxins & Furans CO Oxidation Filtration Fabric Filters & HT CK Series Filter Bags VOCs Dust/PM HC 31

Technology EnviroTex TM 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 Design T: 410-464 F (210-260 C) Dimension: app. 20-40 feet (6-12m) length • No poisoning of catalyst 32

Catalytic filter bag 33

Catalytic Filter Bag 34

Catalytic filter bag Catalyst Fibers 35

Technology TopFrax TM Catalytic ceramic filters Design T: 410-752 F • Each filter consist of a ceramic fiber based filter (210-400 C) impregnated with a catalyst in the filter wall (20 Dimension: 1-3m length 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 36

NO x and NH 3 removal (SCR) 4 NO + 4 NH 3 + O 2 -> 4 N 2 + 6 H 2 O Off-gas Clean gas NH 3 H 2 O NO O 2 N 2 N 2 Gasflow NO N 2 H 2 O O 2 NH 3 NO 2 O 2 Particulate matter (dust) Catalytic filter bag 37

NO x and NH 3 removal (SCR) 38

Removal of VOC’s / Organic HAP CH 2 O + O 2 -> CO 2 + H 2 O Off-gas Clean gas H 2 O VOC O 2 CO 2 N 2 O 2 Gasflow VOC N 2 H 2 O O 2 VOC CO 2 O 2 Particulate matter (dust) Catalytic filter bag VOC = Volatile Organic Compound: CO, Toluene, Benzene, Formaldehyde etc. 39 HAP = Hazardous Air Pollutant

Removal of VOC’s / Organic HAP 40

Furan/dioxin removal Off-gas Clean gas H 2 O Dioxin O 2 CO 2 N 2 O 2 Gasflow Furan N 2 H 2 O O 2 Dioxin CO 2 Furan HCl O 2 Particulate matter (dust) Catalytic filter bag 41

CataFlex TM Catalytic filter bag principle 42

TopFrax TM Ceramic filter principle 43