Control of gaseous emissions and dust in a single-step solution CataFlex catalytic filter bags
2 Control of gaseous emissions along with dust and cut CAPEX - Significant reductions in CAPEX and OPEX compared to alternative technologies - Single-step emission control unit Are regulators putting the squeeze on your business? Authorities in many countries are tightening emission standards by reducing permissible levels and adding new gasses and particles to the list of regulated components. Compliance is costly requiring substantial investments in new abatement technologies. At FLSmidth, we hear producers calling not just for new technologies, but for innovation that makes compliance affordable. That s what the CataFlex catalytic filter bag is all about. CataFlex catalytic filter bag CataFlex is a patent-pending filter bag with embedded catalyst designed to treat off-gasses in high-dust environments found in a wide range of industries and activities, including: - Cement production - Power plants - Bio-mass boilers - Waste incineration - Steel production - Lime production Clean gas Raw gas side Clean gas side HAP* CO 2 CO 2 3 layers woven glass bags with embedded catalyst. One with e-ptfe membrane NH 3 N 2 N 2 NO x O 2 CO Dust Catalyst Catalyst Catalyst O 2 H 2 O Raw gas with dust and pollutants 3 layers glass bags and e-ptfe membrane Dust is collected on the surface Pollutants removal by catalytic reaction Cleaned gas pass CataFlex filter bag * Organic HAP includes formaldehyde, benzene, toluene, styrene, xylene (m-, p-, o-), acetaldehyde and naphtalene.
Embeded catalyst in woven fiber glass bag 3
4 Substantial reduction in technology costs - Exceptional resistance to catalyst poisoning thanks to no contact between catalyst and potentially harmful particles - CataFlex catalytic filter bags can be installed in an existing filter for affordable upgrade How CataFlex works CataFlex is unique as each bag consists of up to three layers of woven fiberglass. Each layer can feature its own unique catalytic formula, enabling a CataFlex bag to remove multiple gaseous compounds and dust in a one-step process eliminating the need for costly, space demanding tail end gas removal equipment and secure future compliance. CataFlex catalytic filter bags are effective at a wide temperature range. The pressure drop across an CataFlex bag is comparable to that of a conventional filter bag, you don t need to invest in new or upgraded ID fans, compressors or similar technologies when upgrading your existing fabric filter to catalytic fabric filter. Single-step emission control unit As the only catalytic filter bag of its kind, CataFlex delivers entirely unique cost-saving benefits for both CAPEX and OPEX compared to separate RTO, RCO and SCR technologies. Typical fabric filter showing a cross section with catalytic filter bags installed
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6 Broad spectrum of regulated pollutants Built on decades of leadership in filtration and catalysis, CataFlex turns yesterday s ordinary filter bag into a powerful dust filtration plus gaseous emissions control system. Dust The outer layer of an CataFlex catalytic filter bag is a PTFE membrane, enabling compliance with the same low dust emission standards as of today. NO X CataFlex uses selective catalytic reduction (SCR) to remove NO X from the off-gas, either by utilizing ammonia contained in the off-gas or via ammonia injection (see graph 1). The NO X is converted to harmless nitrogen and water. NOx removal, % NOx removal performance NOx inlet: 500mg/Nm 3 wet NH 3 slip: 10 mg/nm 3 wet 100 95 90 85 80 75 70 65 NH 3 Ammonia slip control by CataFlex enable better utilization of the injected NH 3 for NO X removal without compromising the NH 3 emission limit. 60 55 50 180 190 200 210 220 230 240 250 Temperature, C Graph 1: More than 90% NOx removal with compliant NH 3 emission
7 Organic air pollutants The catalyst on the CataFlex bags oxidize a wide range of organic compounds incl. cyclic, aliphatic and aromatic hydrocarbons into carbon-dioxid and water. HAPs The 7 HAP species regulated by NESHAP for US cement plants are volatile organic compounds (VOCs) contained in the gas stream and, as such, part of the total hydrocarbon content (see graph 2). CataFlex effectively removes all 7 HAP species. Dioxins and furans CataFlex catalytic filter bags also has the capability to remove D/F by transforming it into harmless compounds. CO Dependent on the catalytic formula the CataFlex bag can control CO emissions. This oxidation is initiated already at very low temperatures. Removal, % CO and HAPs removal CO Toluene 100 90 HAPs 80 70 60 50 40 30 20 10 0 200 210 220 230 240 250 260 270 Temperature, C Graph 2: Removal of HAP species and CO
Partners in innovation CataFlex is the result of a collaborative partnership between two industry leaders, FLSmidth and Haldor Topsoe. FLSmidth is a world leading supplier of sustainable equipment and services to the global minerals and cement industries. The company s air pollution control technologies include a wide range of solutions for reducing particulate matter and gaseous emissions. More than 8,000 FLSmidth air pollution control systems are installed world-wide. Haldor Topsoe is a world leader in catalysis and surface science. The company is committed to helping customers achieve optimal performance and get the most out of their processes and products, using the least possible energy and resources, in the most responsible way. Copyright 2015 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidth.com/apc CM 05-15 200-43 ENG V3 Project Centre Denmark FLSmidth A/S Ramsingsvej 30 DK-2500 Valby Copenhagen Tel: +45 3618 2000 Fax: +45 3630 2030 E-mail: info@flsairtech.com Project Centre USA FLSmidth Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Tel: +1 610-264-6011 Fax: +1 610-264-6170 E-mail: info-us@flsmidth.com Project Centre India FLSmidth Private Limited FLSmidth House 34, Egatoor, Kelambakkam (Rajiv Gandhi Salai, Chennai) Tamil Nadu 603 103 Tel: +91-44-4748 1000 Fax: +91-44-2747 0301 E-mail: salesairtech-in@flsmidth.com