Flue Gas Cleaning

Flue

Gas

_071

029_

GB

Flue Gas Cleaning

Advanced Filter Technology and Know-How The advanced Simatek Flue Gas Cleaning technology is based on long experience and a great number of reference plants within the field of high-temperature filtration. Simatek Flue Gas Cleaning systems are in operation in different industries all over the world, and the continuously ongoing development of the technology places Simatek as technology leader in many segments. The unique SimPulse 3C filter concept holds a lot of remarkable features, one of which is the sophisticated "long bag principle", ensuring an efficient pulse-jet cleaning of filter bags of up to even 12 metres length. This facility allows for the application of cylindrical corrosion-proof filter modules for almost any capacity required. Compared to conventional filter systems the Simatek filter technology consumes only very little energy, which is particularly well demonstrated on large filters. Especially with submicron particles and absorption of acid gases as well as parallel adsorption of heavy metals and dioxins, the SimPulse 3C filter has remarkable advantages.

In due consideration of actual parameters as the size of the plant, the geographical area, and local partners, we are offering the supply of key components combined with engineering support and supervision for local co-production.

We provide: Innovative technology An extensive process knowledge A wide application knowledge from

more than 175 flue gas references A technology kept abreast of future

legal emission requirements Supervision of local co-production Well-developed After-Sales Service

organisation

Flue Gas Filtration

Fields of Application High-temperature particle filtration is in general most efficiently performed in a self-cleaning pulse-jet filter. Considering the particle size, the flue gas composition, and the flue gas volume, we will recommend the proper bag quality for a given filtration job. Together with the most innovative suppliers of filtering material, Simatek has over the years taken part in the improvement of filtering material for special applications and fulfilment of the strictest legal emission requirements. The optimum bag quality is selected in due consideration of the parameters below:

Gas temperature Gas composition (contents of acid gases, if any) Dew point (acid and water) Contents of oxygen Chemical aggressive compounds Particle specification Acid / alkaline dust Emission requirements

Typical Bag Qualities and their Applicability 1=excellent, 2=good, 3=moderate, 4=restricted

Material Simatek Temperature*) Resistance to

Code Continuous

°C

Peaks

°C Hydrolysis Acids Alkalis Oxidation

Homopolymer acrylic DT 120 125 2 2 3 2

m-Aramide NO 200 220 3 3 3 2

Polyphenylene sulfide PPS 190 220 1 1 1 3

Polyimide PI 240 260 2 2 3 2

Polytetrafluoroethylene TF 250 280 1 1 1 1

Glass GL 250 280 1 1 1 1

*) Chemical gas stream conditions may require a lower continuous operating temperature to be maintained

To achieve the desired filtration capability, chemical resistance, and mechanical strength, the filtering material will probably be composed by more material qualities, either in the shape of mixed fibres or as layers of different fibre qualities. An especially high separation degree of submicron particles is achieved by surface filtration based on microfibre technology or lamination of microporous membranes. In specific cases we guarantee emission values of less than 1 mg/Nm3 for surface filtration.

Biomass Boilers

Small- and Medium-Sized FGC Filters The emission requirements for district heating and combustion of biomass fuels often demand a very efficient Flue Gas Cleaning. Even small heating plants have to meet emission requirements of max. 20 mg/Nm³ or even lower values. From a technical point of view, the small- and medium-sized heating plants require the same Flue Gas Cleaning quality as large plants. The requirements for the small plants actually tend to be more complex, considering possible unstable temperatures, frequent starts, inhomogeneous fuel and risk of sparks.

For the small-sized heating plants we recommend the SimPact 4T filter concept, and for the medium-sized heating plants we prefer the SimPulse 3C filter concept. Both filter concepts are characterized by cylindrical filter modules with possible integrated pre-separator and spark arrester. Compared to conventional bag filters and electrostatic precipitators, the SimPulse 3C is a very compact filter unit.

Before, ESP not meeting emission requirements Today, SimPulse 3C; Emission <5 mg/Nm³

Straw-fired district heating plant Filter for waste-wood boiler

Power Plants

Modular FGC Filters The concept of applying cylindrical filter modules for Flue Gas Cleaning is a proven solution to prevent corrosion. The SimPulse 3C filter is the only pulse-jet filter concept on the market, providing an optimum utilization of the "long bag" principle with a number of significant features: Individual pulse-jet cleaning of filter

bags of up to 12 metres length Low-pressure – high-pulse energy Low energy consumption On-line cleaning

Long lifetime of filter bags Flat bottom design (no dust build-up) Modular design with the possibility of

large filter areas

The combination of a cylindrical design and downflow filtration prevents undesirable tempera-ture gradients and facilitates tall filter modules with a minimum footprint.

Typical Fields of Application Biofuel Waste Fossil fuels

Power plant, paper & pulp industry Filter area: 9,500 m² Capacity: Approx. 500,000 m³/h

SimPulse 3C Filter Module Module area up to 3,500 m²

Waste Incineration

Acid Gases, Heavy Metals, and Dioxins In recent years we have demonstrated our market position in Scandinavia as one of the most important suppliers of Flue Gas Cleaning technology for waste incineration. More than 50 reference plants include incineration capacities from 200 kg/h up to more than 20 t/h. In due consideration of the parameters as type of fuel, flue gas temperature, and humidity Simatek proposes either of the two types of absorption; Dry Absorption or Semi-Dry Absorption. Dry absorption is the simplest solution and is designed to fulfil the strictest legal requirements, including the EU Directive concerning waste incineration and the 17. BImSchV. For the absorption of acid gases, different qualities of hydrated lime Ca(OH)2 or sodium-bicarbonate NaHCO3 are added. For the removal of heavy metals and dioxins, activated carbon or lignite coke is the typical adsorbent. Simatek References: Municipal waste Industrial waste Hospital waste Sludge Waste oil

M

M

M M

M M M

M

Ca(OH)2

orNaHCO3

ActivatedCarbon

QUENCH

REACTOR FILTER

Semi-dry absorption is relevant for:

High flue gas temperature,

typically >160ºC

Need of extra high degree of

SOx reduction

Dry Absorption

Simatek dry absorption systems

efficiently remove acid gases like SOx,

HCl, and HF. If adsorbent is injected in

the same process, heavy metals and

dioxins are removed as well.

Semi-dry Absorption

The sorbent costs may be reduced by

installing a spray absorber with lime-

milk injection.

Filters for Waste Incineration

Smelters

Primary and Secondary Flue Gas Cleaning The SimPulse 3C concept is unique for either primary or secondary cleaning of the flue gas from smelting processes. From the actual capacity and flue gas composition it is determined whether one or more filter modules are to be incorporated, and whether absorption of acid gases and parallel adsorption of toxic components are required. The technology is suitable for gas-fired furnaces, electric furnaces, cupola furnaces, and the like. The SimPulse 3C "long bag principle" is particularly advantageous for high capacities.

Smelting Pot

Smelting Processes Metals Iron Minerals Glass Carbogrit

Converter

Smelter – Scrap Aluminium Removal of HCl and dioxins

Smelter – Ferro Manganese

Capacity: 700,000 m³/h

Local Production

Local Co-Production of Filter Plants Filter plants for Flue Gas Cleaning typically comprise a number of complex compo-nents along with a range of silos, steel structures, and conveying systems for ash/sorbents. Major part of these units may be manufactured locally, thus rendering possible savings on transport and production costs. Simatek possesses great experience in the field of supplying key components and technical support for the erection and commissioning of Flue Gas Cleaning plants in Europe, Asia, and Africa respectively. The scope of supply will be tailored to the local manufacturer in question. Supervision of local co-production and commissioning of the filter plant is safe-guarded by skilled Simatek engineers. Examples of Filter Clusters:

Filter Module Filter Cluster

Bag

Length Dia. Bag Dia. Area Modules Area A/C-ratio Capacity m mm ø mm m2 Pcs. m2 m3/m2/min. m3/h

JM 280 10.0 4,400 140 1,232 4 4,926 1.0 295,561 JM 280 10.0 4,400 140 1,232 4 4,926 1.5 443,342 JM 280 10.0 4,400 140 1,232 4 4,926 2.0 591,122 JM 336 11.0 4,600 140 1,626 4 6,502 1.0 390,141 JM 336 11.0 4,600 140 1,626 4 6,502 1.5 585,211 JM 336 11.0 4,600 140 1,626 4 6,502 2.0 780,281 JM 400 12.0 5,600 160 2,413 4 9,651 1.0 579,058 JM 400 12.0 5,600 160 2,413 4 9,651 1.5 868,588 JM 400 12.0 5,600 160 2,413 4 9,651 2.0 1,158,117 JM 560 12.0 6,800 160 3,378 4 13,511 1.0 810,682 JM 560 12.0 6,800 160 3,378 4 13,511 1.5 1,216,023 JM 560 12.0 6,800 160 3,378 4 13,511 2.0 1,621,363

SimPulse 3CS Top Section Including Pulse Air Distributor (PAD)

Subject to alterations