CEMENT GAS CLEANING AND COOLING SOLUTIONS

Transcription

1 CEMENT GAS CLEANING AND COOLING SOLUTIONS

2 CFD simulation SINCE LATE 2005 ECOSPRAY HAS DEVELOPED, DESIGNED AND INSTALLED HUNDREDS OF GAS COOLING AND CLEANING SYSTEMS, INCLUDING DUST REMOVAL, DeNOx AND DeSOx IN DIVERSE INDUSTRIAL APPLICATIONS.

3 EVAPORATIVE COOLING TOWERS Evaporative cooling towers are employed to cool and humidify hot gases, from above 600 C down to 150 C or less, to optimize treatment in a bag house or an electrostatic precipitator. Ecospray cooling systems are designed and developed using detailed analyses, including physical modeling and Computational Fluid Dynamics (CFD) simulations of gas distribution and tower geometries to prevent maldistribution of the gas and poor gas/water interaction.

4 Ecospray offers three proprietary cooling system options, each available with single or multiple nozzles, each with different advantages and characteristics in order to always provide the most suitable solution for the specific application. DUAL FLUID - Injection and control rack DUAL FLUID - Spray lance DUAL FLUID SPRAY LANCE SYSTEMS DUAL FLUID - Compressed air assisted nozzle The DUAL FLUID evaporative gas cooling system consists of a proprietary compressed air assisted nozzle technology that uses only 35 Nm 3 /h of air for each m 3 /h of water injected. In order to save compressed air consumption, all Ecospray systems are equipped with proprietary regulating valves that allow the systems to maintain the air pressure strictly consistent with the water pressure and to reach a regulation turn down of up to 1:20 or more. This technology achieves the smallest possible droplets size compared to the other available solutions. GAS COOLING

5 SINGLE FLUID SPRAY LANCE SYSTEMS The SINGLE FLUID lance and nozzles system is designed to produce variable flow rates with good droplet size, including regulation under critical operating conditions. The water in the swirl chamber of the nozzle is sprayed into the gas cooling tower and partially spilled-back through a return orifice that leads to the storage tank. The droplets obtained are relatively larger than those obtainable with the dual fluid technology. As a result, a lower consumption of electricity is required. SPILL AIR LANCE SYSTEMS The SPILL AIR solution produces a spray quality similar to the air assisted nozzle but without using a compressor. The operational principle integrates the advantages of a single fluid nozzle at 40 bar and a dual fluid one. The air is generated by a blower and then sent into the area of droplets formation. The air jet direction (axial - centripetal) reduces the spray angle and turns it from an empty-cone into a full-cone, greatly improving water-gas distribution. The speed of the water droplets is increased by enhancing the heat exchange capacity, consequently reducing the evaporation time.

6 ECO-NOx TM SCR (SELECTIVE CATALYTIC REDUCTION) DeNOx catalyst element In SCR systems either ammonia or urea is sprayed into the gas stream, but at relatively low temperatures ( C) with the conversion reaction accelerated by suitable catalysts. ECO-NOx TM SCR performance typically results in NOx reduction greater than 98% with an ammonia slip below 5 mg/nm 3. Due to a specific expertise in spray liquid applications, Ecospray has developed a nozzle system that is able to achieve the most extensive and effective level of reagent droplet spray dispersion without using distribution grids downstream of the NH 3 injection points. This capability also prevents fouling and maldistribution in the pipes. ECO-NOx TM SNCR (SELECTIVE NON-CATALYTIC REDUCTION) In SNCR systems either ammonia or urea solution is sprayed into the gas stream at high temperature ( C ). The reagent converts NOx into N 2 and H 2 O vapor through reactions that are fast enough not to require the aid of catalysts. Within an optimal range of process variables, such as injection temperature, reagent distribution, mixing and residence time, high performance (up to 60% and greater) can be achieved without significant ammonia slip at the stack. Ecospray advanced systems consist of several stages of spray lances positioned in select areas of the reaction chamber in order to insure operation under the most favorable process conditions, and to achieve maximum efficiency at both reduced and full load in accordance with regulations. Adjustment and dilution with DEMI water can also play an important role in optimizing the overall system. GAS CLEANING

7 ECO-NOx TM SNCR WITH UREA EXTERNAL GASIFICATION This system, developed and patented by Ecospray, uses tertiary hot air to allow the conversion of urea-water-solutions into a gaseous stream of ammonia and hot air. Such reaction takes place under controlled temperature conditions inside a dedicated reactor containing a specific catalyst bed. The catalyst bed at the bottom of the reactor ensures complete conversion of urea into ammonia. The main advantages of external gasification of urea are enhanced reactivity inside the pre-calciner and better mixing of reactant with the flue gas. Therefore, Ecospray s unique system reduces the consumption of urea to less than half than that required by conventional SNCR systems while achieving the same NOx removal efficiency, with consequent energy savings.

8 HIGH TEMPERATURE FILTRATION SYSTEMS ECO-CER TM dust collector - Rezzato plant (Italy) Following extensive testing and optimization in a cement plant, Ecospray has developed the ECO-CER TM dust collector that enables gases to be treated at high temperatures, more than C, with excellent dust removal performance. This unique high filtration system is of a proprietary design and very robust fabrication. It is comprised of ceramic filter elements in monolithic forms of 150 mm outer diameter and 3 or more meters in length. Ecospray is the first to successfully employ this technology in the cement industry. Ceramic filter elements work at very high temperatures (up to 800 C) and sustain a high level of efficiency for more than 16,000 hours of operation. Additionally, these ceramic elements can also be impregnated with special catalysts to allow the filter to dually function as a dry reactor for removing NOx, CO and VOC with excellent removal efficiency (up to 99%). Ceramic filter elements GAS CLEANING DUST REMOVAL

9 ECO-JET TM BAG FILTERS Bag filters are the most commonly used systems for reducing dust emissions in industrial applications. Many key factors such as gas temperature and composition, dust properties and load, etc., must be considered for a bag filter design. It is essential, in order to achieve the highest level of efficiency and longest life, to effectively set up the gas flow distribution/ velocities into the bag filter and choose the most appropriate materials/components for its construction. The most critical is the selection of the appropriate filtering media. Ecospray s field experience and technological competencies, as well as expertise in the use of modeling and CFD simulations, ensure that the ECO-JET TM BAG FILTER is an extremely reliable, efficient and long-lasting filtration solution under a broad range of operating conditions and gas volumes (from 1,000 up to 500,000 m 3 /h). Supportive of each specific application s requirements, Ecospray studies and adopts the optimum design (e.g. with/without pre-chamber, compartments, walk-in plenum, etc.) and cleaning system (e.g. ON/OFF line, high/low pressure) for every installation of ECO-JET TM BAG FILTER. M

10 ESP UPGRADE SOLUTION Electrostatic Precipitators (ESPs) perform well for dust removal, but are increasingly unable to comply with new and stricter regulations on particulate emissions. An innovative, patented solution developed by Ecospray consists of a retrofit dedusting system that upgrades the ESP, increasing its efficiency to a filtration level that is equal to and more reliable than current bag or ceramic filters. Unlike an ESP conversion in a conventional hybrid filter (i.e. where a high quantity of bag filters are installed in the ESP final section), this new Ecospray solution is of a far more contained dimension with limited removal/installation of existing/new parts required. As a result, implementation costs are significantly lower. Furthermore, this solution requires less maintenance than conventional hybrid, bag and ceramic filters, therefore operating costs are also lower. The new Ecospray ESP upgrade solution embeds into the electrostatic precipitator a layer of filtering elements of the wall flow type. These elements are characterized by significant compactness and are of modular construction, which enables a short assembly time and minimal modifications to the ESP structure if retrofitting to an existing unit. This solution can also be designed-in for new ESPs. Along with a very high level of dedusting performance, the Ecospray solution s wall flow elements, perform at a more consistent level of filtration over the life of the elements compared to those of traditional filtering components. They are constructed of silicon carbide, one of the most mechanically and chemically resistant materials available. Furthermore, the filter elements are able to work at very high temperatures (up to 600 C), under operating conditions not tolerable by the other known filtering elements. In the new Ecospray ESP upgrade solution, as a result of the combined action of the ESP (that acts as primary separator achieving dust levels below 100mg/Nm 3 ) and the wall-flow filtering layer (that acts as a highly effective and efficient polishing stage), the dust content in the gas emissions downstream of the ESP can reach a level equal to 2-3mg/Nm 3. Of added value, the filtration elements can be coated with catalysts, expanding the capability of the system; either oxidation catalysts for the simultaneous reduction of CO, HC and VOC or DeNOx catalysts for high efficiency NOx removal. GAS CLEANING DUST REMOVAL

11 OTHER APPLICATIONS: MARINE High performance Exhaust Gas Cleaning systems (ECO-EGC TM ) for the marine industry. Ecospray s systems address all regulated pollutants contained in the exhaust gases of marine diesel engines, in particular on large ships such as cruise vessels, cargo ships and ferries. OUR SYSTEMS: - GAS CLEANING - DeNOx (SCR SNCR) - DeSOx AND ACID GAS REMOVAL - PARTICULATE AND SOOT REMOVAL - GAS COOLING - FOGGING - BIOGAS UPGRADING ENERGY AND INCINERATION Integrated systems specifically designed for the unique characteristics and needs of the power generation, incineration and waste to energy industries. Ecospray s systems have been installed in energy production operations employing biomass boilers, coal and oil fueled processes, and the gas turbines of cogeneration plants (diesel generators powered by natural gas, biomass and diesel). STEEL AND METALS De-dusting systems with bag filters, wet filters and variable throat scrubbers, along with high performance spray cooling towers. GLASS AND CERAMIC Combined NOx and particulate matter removal systems for glass and ceramic applications, based on high temperature filtration using catalytic ceramic filters with ammonia or urea injected at the inlet of the filter/reactor. Solutions such as the injection of calcium or bicarbonate based sorbents to remove acidic pollutants such as hydrofluoric acid and/or SO 2, in conjunction with the dust removal and denitrification steps, employing the same filtering system. CHEMICAL Gas cleaning and conditioning systems for the chemical industry, designed to maximize the removal of dust, heavy metals, dioxins and NOx, as well as acid gases (SOx, Hcl, HF, etc.).

12 HEADQUARTERS ECOSPRAY TECHNOLOGIES S.r.l. Via Circonvallazione, Alzano Scrivia (AL) - Italy Phone Fax info@ecospray.eu NORTH AMERICAN OPERATIONS 33 West 19th Street New York - NY Phone +1 (646) Fax +1 (646) pacinelli@ecospray.eu MIDDLE EAST AND NORTH AFRICA OPERATIONS Blue Tower - Office 7035 P.O. Box 2685 Abu Dhabi U.A.E. Phone Fax l.salvato@ecospray.eu OUR PARTNERS GREECE & CYPRUS - OCEANKING TECHNICAL & TRADING SA info@oceanking.gr POLAND - B4S Sp.z o.o. zc@b4s.pl RUSSIA - SPRAYLAB SA spraylabriva@gmail.com SWEDEN - PNR Nordic AB info@pnrnordic.se R09 Copyright 2016 by Ecospray Technologies S.r.l. All rights reserved