Catalytic Filter for Dioxin Control - Experience and Case...

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Catalytic Filter for Dioxin ControlCatalytic Filter for Dioxin Control

-- Experience and Case StudiesExperience and Case Studies

Zhengtian XuW.L. Gore & Associates, Inc.

Remedia is a trademark of W.L. Gore & Associates, Inc.

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AgendaAgenda

• Technology Introduction

• Application Experience: ProvenPerformance Worldwide

– IVRO Municipal Waste Incinerator-Belgium

– Phoenix Medical Waste Incinerator-USA

– Secondary Aluminum Production Plant-UK

– Ashibe Municipal Waste Incinerator - Japan

• Conclusions

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Dioxin Control TechnologiesDioxin Control Technologies

• Powder Activated Carbon (PAC)injection

• Selective Catalytic Reduction (SCR)

• Catalytic filters

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Carbon injection

Boiler

ESP

Lime

Bag House

StackFurnace

PAC InjectionPAC Injection –– Process DiagramProcess Diagram

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PAC InjectionPAC Injection

• Injection of PAC up stream of baghouse

• Most D/F captured at the filter bag

• Transfer D/F from gas to solid phase

• Efficiency varies based on injection rate

• Proven and reliable

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PAC InjectionPAC Injection

• Move D/F from air to solid waste

• Increase disposal cost

• Active system - high maintenance

• Safety - hot spots in filter house

• Large area required for carbon silo

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Boiler

Lime

Bag House

StackFurnace

SCRHeat

Selective Catalytic ReductionSelective Catalytic Reduction

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Selective Catalytic Reduction

• High equipment & catalyst cost

• High temperature requirement(>250 °C)

• High pressure loss - energy costs

• Large footprint for catalyst house

• Vulnerable to dust

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Remedia Catalytic Filter SystemRemedia Catalytic Filter System

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• Reduces the total Dioxin released tothe environment

• Easy to adopt and use

• Cost effective

• Provides reliable & consistentoperation

Why REMEDIA Filter??Why REMEDIA Filter??

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The Combination of Two Proven Technologies:The Combination of Two Proven Technologies:

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Uncatalyzed

reaction

Products

Catalyzed

reaction

Ea. (uncat)

Ea. (cat)

E

n

e

r

g

y

Reaction Pathway

CatalysisCatalysis

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TiO2V2O5

O

O2

3

1

4 6

7

8

9

Clx Cly

Catalytic Destruction of PCDD/FCatalytic Destruction of PCDD/F

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TiO2

V2O5

CO2

CO2

H2O

H2OHCl

HCl


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• PCDDsC12HnCl8-nO2 + (9+0.5n)O2 ==>(n-4) H2O + 12 CO2 + (8-n) HCl

• PCDFsC12HnCl8-nO + (9.5+0.5n)O2 ==>(n-4) H2O + 12 CO2 + (8-n) HCl


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REMEDIA Catalytic FilterREMEDIA Catalytic Filter

• High PCDD/F removal efficiency

• Destruction of the PCDD/F molecule

• Lower disposal cost

• Passive system

• Low temperature requirement (150-250°C)

• Use existing filter house

• Lower pressure loss - energy costs

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REMEDIA Catalytic Filter System is an evolution of 2 proven technologies:…………….

REMEDIA Catalytic Filter in ActionREMEDIA Catalytic Filter in Action

& CatalysisSurface Filtration

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RawGas

< 0.1

ng/Nm³Dioxin

Highly ContaminatedDioxin/Waste

Adsorption Process

Less Waste to Landfill> 90% Dioxin Destroyed

REMEDIA Catalytic Filter System

Remedia Catalytic Filter vs. AdsorptionRemedia Catalytic Filter vs. Adsorption

RawGas

< 0.1

ng/Nm³Dioxin

ActivatedCarbon

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CatalyticTower

SCR Catalytic Reactor System REMEDIA CatalyticFilter System

Remedia Catalytic Filter vs. Catalytic ReactorRemedia Catalytic Filter vs. Catalytic Reactor

RawGas

RawGas

< 0.1

ng/Nm³Dioxin

Re-HeatSystem

< 0.1

ng/Nm³ Dioxin

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AgendaAgenda

• Technology Introduction

• Application Experience: ProvenPerformance Worldwide

– IVRO Municipal Waste Incinerator-Belgium


– Secondary Aluminum Smelter-UK


• Conclusions

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• Municipal Waste Incinerators

• Medical Waste Incinerators

• Industrial Waste Incinerators

• Pyrometallurgical

• Crematoriums

Worldwide REMEDIA CatalyticWorldwide REMEDIA Catalytic

Filter System ApplicationsFilter System Applications

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Worldwide Proven PerformanceWorldwide Proven Performance

Creative TechnologiesWorldwide

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Worldwide Proven PerformanceWorldwide Proven Performance

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1

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3

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8

Dio

xin

TLB IVBO Karume Ashibe Phoenix Kasugai

Before Remedia

After Remedia

Dio

xin

(n

g T

EQ

/Nm

3)

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• Over 50 applications worldwide meetingthe most stringent emission regulations.

• Applications in 10 countries.

• Over 130 years cumulative globalexperience.

• Thousands of successfulmeasurements.

Proven Performance You Can Rely OnProven Performance You Can Rely On

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IVRO Municipal Waste IncineratorIVRO Municipal Waste Incinerator -- BelgiumBelgium

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IVRO Municipal Waste IncineratorIVRO Municipal Waste Incinerator

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Reliable PerformanceReliable Performance

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RawGas

Adsorption Process REMEDIA Catalytic Filter System

IVRO Comparison TestingIVRO Comparison Testing

RawGas

ActivatedCarbon

1ngTEQ/Nm3

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• Over 10 measurements, gas phase dioxinsaveraged 75% of total.

• Dioxin emissions well below 0.1 ngTEQ/Nm3 for over 6 years.

• Gas phase dioxin destruction greater than99% for all isomers.

• Dust emissions less than 0.4 mg/Nm3

• Only Belgian incinerator to have never beenshut down for dioxin.

IVRO ResultsIVRO Results

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Baltimore Regional Medical WasteBaltimore Regional Medical Waste

IncineratorIncinerator -- USAUSA

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• Largest dedicated facility in the world

• Capacity: two incineration process lines,each rated at 77 metric tons per daythroughput

• Service area: within a radius ofapproximately 400 kilometers fromBaltimore, Maryland

Plant InformationPlant Information

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Process Flow DiagramProcess Flow Diagram

Primary Combustion

Chamber

Secondary Combustion

Chamber

Tertiary Chamber

Boiler

Wat

er Q

uen

ch (

inac

tiv

e)

Dry

Inje

ctio

n R

eact

or

Baghouse

Trona

Bottom Ash

Spent Sorbent / Fly Ash

To ID Fan

and Stack

Gas

Waste

Gas

Gas

Air

Air

Air

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• Phoenix Introduced to Catalytic Filter Technologyby Gore in Late 1997

• Advantages Compared with PAC Injection

• Destruction vs. Adsorption

• Passive Solution, No Active Chemical Feeding

• Conversion is Simple (Install New Filters)

• Reduction of Potential Future Liability

• Advantages of ePTFE Filter Media

• Phoenix Refitted Both Baghouses with CatalyticFilters in May - June 1999

Control Technology EvaluationControl Technology Evaluation

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Measurement Results: PCDD/FsMeasurement Results: PCDD/Fs

0.098

3.35

0.0550

1

2

3

4

RUN 1 RUN 2

PC

DD

/F C

on

cen

trati

on

(ng

TE

Q/d

scm

@ 7

% O

2)

RAW GAS

CLEAN GAS

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Measurement Results: PCDD/FsMeasurement Results: PCDD/Fs

5.5

2.3

0.077

2.3

0

1

2

3

4

5

6

7

Historical

Value (1998)

New

Emission

Guideline

Guaranteed

Value

Catalytic

Filter (mean)

Cle

an

Ga

s

PC

DD

/F C

on

ce

ntr

ati

on

(ng

TE

Q/d

scm

@ 7

% O

2)

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• Overall, 98.4% of PCDD/F (gas + solidphase) were removed– 97.7% of gas phase PCDD/F were destroyed

– 99.9% of solid phase PCDD/F were removed

• PCDD/F emission < 0.1 ng TEQ/dscm

• 99.95% of the particulate was removed

Key FindingsKey Findings

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Secondary Aluminum Production PlantSecondary Aluminum Production Plant -- UKUK

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Process Flow DiagramProcess Flow Diagram

shredder decoater

incineratorheat

exchanger

melting furnaceAl shreds

dilution air

cans

bag house

raw gas

sampling port

clean gas

sampling portdilution air

fan

fan

temperature

after fan

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Catalytic FiltrationCatalytic Filtration

1.5

0.0390.068

0.027

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

PC

DD

/F C

on

cen

tra

tio

n

[ng

I-T

EQ

/Nm

3 @

11

%O

2]

January 2000 March 2000 November 2000 April 2001

Inlet

Outlet

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• Successful operation for more than 4years

• Total removal efficiency more than97%

ResultsResults

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Ashibe Municipal Waste IncineratorAshibe Municipal Waste Incinerator -- JapanJapan

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43Fig. Scheme of Ashibe MSWI

Heat

Exchanger

Induced

Draft Fan

Gas C

oo

ler Baghouse

Furnace

Lime

Injection

sta

ck

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0

2

4

6

8

10

12

PC

DD

/F [

ng

WH

O-T

EQ

/N

m3

@ 1

2%

O2]

Start-Up Steady State Shut-Down

Inlet

Outlet

Dioxin Destruction vs. Operating ConditionDioxin Destruction vs. Operating Condition

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0.020 0.018 0.021

3.1

4.5

7.5 1.7

3.9

0.79

0.003 0.001 0.003

0

2

4

6

8

10

12

Start-up Normal Shut-down

IN OUT IN OUT IN OUT

Particulate phase

Gas phase

PC

DD

/F,

ng

WH

O-T

EQ

/m

3N

@12%

O2

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T4C

DD

s

P5C

DD

s

H6C

DD

s

H7C

DD

s

O8C

DD

s

T4C

DF

s

P5C

DF

s

H6C

DF

s

H7C

DF

s

O8C

DF

s

BH outlet

0

20

40

60

80

100

120

140

160

BH inlet

PC

DD

/F

(ng

/ N

m3

@12%

O2)

Dioxin Isomer Distribution: Inlet/OutletDioxin Isomer Distribution: Inlet/Outlet

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• Greater than 99.5% dioxin control for alllevels of inlet concentration.

• Effective dioxin destruction for all stages ofdaily batch process.

• Consistent and efficient destruction of all TEQisomers.

• All dioxin emission values significantly below0.1 ng regulation.

Ashibe ResultsAshibe Results

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AgendaAgenda• Technology Introduction

• Remedia Filter Bag Processing

• Application Experience: ProvenPerformance Worldwide– IVRO Municipal Waste Incinerator-Belgium


– Secondary Aluminum Production Plant-UK


• Conclusions

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Remedia Catalytic Filter BagRemedia Catalytic Filter Bag

• Reduces the totalDioxin released to theenvironment

• Easy to adopt and use

• Cost effective

• Provides reliable &consistent operation

Remedia Catalytic Filter Bag

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Industry RecognitionIndustry Recognition

2001 Environmental2001 Environmental

InnovationInnovation

Product of theProduct of the

Year AwardYear Award

2002 J. Deane2002 J. Deane

Sensenbaugh AwardSensenbaugh Award

OutstandingOutstanding

Achievement in theAchievement in the

Field of Air PollutionField of Air Pollution

ControlControl

Catalytic Filter for Dioxin Control - Experience and Case...

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