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Control Technologies
Compendium
Prepared by
Y.M. Fahmy, P. Fornasiero, S. Zinoviev and S. Miertus
This present Compendium has been developed as part of the programme of the
International Centre for Science and High Technologies of the United Nations Industrial
Development Organization (ICS-UNDIO). UNIDO is a specialized agency of the United Nations
dedicated to promoting sustainable industrial development in developing and transition-
economy countries. It harnesses theforces of government and the private sector to foster
competitive industrial production and international industrial partnership and promote
socially equitable and environmentally friendly industrial development. The International
Centre for Science and High Technology is an institute within the framework of UNIDO,
with headquarters in Trieste, Italy at the AREA Science Park. The Centres mandate is the
transfer of know-how and technology in favour of developing countries and is based on
the premise that competitive industrial technological capability cannot be built-up without
adequate scientific knowledge and commitment to a sustainable development approach
based on new and environmentally friendly technologies.
In the programme of the Area of Pure and Applied Chemistry one of the
subprogrammes is dedicated to Catalysis and sustainable Chemistry. The activities with this
subprogramme are focused on specific topics such as catalysis for exploitation renewable
resources, catalysis for environmentally friendly processes and catalytic technologies for
cleaner production.
The rapid implementation of various technologies focused primarily on increasing
the economic efficiency of industry has had an important environmental impact.
Industry, besides of transport - is the largest consumer of natural resources and
one of the main contributors to overall pollution. The industrial sector generates pollutants
such as organic substances, CO2, SOx and NOx emissions, hydrocarbons, volatile organic
compounds (VOC) and persistent organic pollutants (POPs). Is compendium focuses on air
pollution control technologies including catalysis for pollution reduction and prevention both
for stationary and mobile applications.
Stanislav Miertus
Chief of Area
Pure and Applied Chemistry
3
Contents
5
5.2.5 Biological Oxidation 66
5.2.6 General Applicability of VOC Control Systems 67
5.3 Some Commercial Technologies 68
5.3.1 Oxidizer Types 68
5.3.2 Direct Fired Thermal Oxidizers (DFTOS) 69
5.3.3 Recuperative Oxidizers 69
5.3.4 Regenerative Thermal Oxidizers (RTOs) 70
5.4 Example of Commercial Technologies 71
5.5 Examples of Commercial Catalysts 73
5.5.1 Engelhard Catalysts 73
5.5.2 Photocatalytic Self-cleaning Ceramic 73
5.6 References 74
6
10.2.1 Principle and Operation of TWCs 115
10.3 Next Generation Technology for Emissions Control 119
10.3.1 Hydrocarbon Adsorber Systems 119
10.3.2 Electrically/Chemically Heated Catalyst Systems 120
10.3.3 Close-coupled Catalyst (CCC) 120
10.3.4 New Catalysts 121
10.4 Diesel Engine Emissions 121
10.4.1 Emission Formation in Diesel Engines 122
10.4.2 Diesel Fuel 123
10.4.3 World Diesel Emission Standards 125
10.4.4 Diesel Emission Control Technologies 126
10.4.5 Advanced Diesel Engine Technologies 127
10.4.6 Diesel Oxidation Catalyst 128
10.4.7 Lean NOx Catalyst 128
10.4.8 Selective Catalytic Reduction 129
10.4.9 NOx Adsorbers 130
10.4.10 Diesel Particulate Filters 130
10.5 Diesel Filter Regeneration 131
10.6 Other Control Technologies 133
10.7 Future Trends 133
10.8 References 134
11 Appendices 137
11.1 Web Directory 137
11.2 Glossary 138
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AIR POLLUTION CONTROL TECHNOLOGIES
As the population grows, industry expands to make more and increasingly diverse
products and the use of transport increases. Therefore the emissions of some pollutants
is inevitably increasing. High pollution emission have already, on several occasions and in
several places, led to ground level concentrations that were associated with dramatic rises
in mortality and morbidity.
The term air pollution is the presence in the atmosphere of solid particles, liquid
droplets or gaseous compounds, which are not normally, present or which are present in a
concentration substantially greater than normal and harmful to living organisms and to the
environment.
Common air pollutants and the relative main sources are presented in Table 1.1
9
POLLUTANTS AND POLLUTION SOURCES
NOx emission per year: > 30 mmt (millions of metric tons) globally, 21 mmt in the
USA, 95 % from vehicles and power sources.
Non-CH4 VOCs emission per year: 79 mmt in the USA, 87% from stationary and
mobile engines.
CO emission per year: > 107 mmt globally, 79 mmt in the USA, 80% from mobile
engines.
SO2 emissions per year: > 42 mmt globally, 22 mmt in the USA.
CH4 emissions per year: 160 mmt from natural sources (rice, animals); 370 mmt
from human derived sources (cars, refineries, coal mines, and fills); 27.2 mmt from US
human sources, but only 0.12 mmt of CH4 from US industry; 500 adsorbed by the Earth.
N2O emissions per year: 11 mmt from natural sources; 3 mmt from human
sources (fertilizer, fuel oil, cars); 10 mmt adsorbed by the Earth.
CO2 emission per year: 160000 mmt generated naturally, worldwide; 8000 mmt
from human derived sources, global; 165000 mmt adsorbed by the Earth, the balance is a
global increase of 3000 mmt per year; 1375 mmt CO2 from energy production in the USA.
In the year 2005, the dramatic dimension of the problem has been confirmed by
the US Department of Energy (2). The evidences clearly indicate that CO2, CO, VOCs, NOx,
and SO2 represent major air pollutants. Notably, although the amount of released N2O is
relatively small, there is a growing attention to this pollutant due to its long lifetime in the
atmosphere (over 150 years) (3-6)
Immediate effects: sudden increase in air pollution has often been associated with
immediate increase in the mortality and morbidity especially due to respiratory
disease.
Delayed effects: chronic bronchitis, lung cancer, dermatitis due to irritants and
carcinogens in smoke and other pollutants.
Carbon monoxide (CO) is one of the most toxic gases emitted by automobiles. It
interferes with absorption of oxygen by hemoglobin (red blood cells), impairs perception and
thinking, slows reflexes, cause drowsiness, brings or angina and can cause unconsciousness
and death; it affect growth in pregnant women and tissue development of young children.
10
AIR POLLUTION CONTROL TECHNOLOGIES
Sulfur dioxide (SO2), has irritating capacity and have development of bronchial
obstruction. It has also settled down that the lingering exposition increase the risk of
development of sharp and chronic conjunctivitis.
Ozone (O3) Ozone can irritate lung airways and cause inflammation much like a
sunburn. Other symptoms include wheezing, coughing, pain when taking a deep breath, and
breathing difficulties during exercise or outdoor activities. People with respiratory problems
are most vulnerable, but even healthy people that are active outdoors can be affected when
ozone levels are high. Repeated exposure to ozone pollution for several months may cause
permanent lung damage. Anyone who spends time outdoors in the summer is at risk,
particularly children and other people who are active outdoors.
Even at very low levels, ground-level ozone triggers a variety of health problems
including aggravated asthma, reduced lung capacity, and increased susceptibility to
respiratory illnesses like pneumonia and bronchitis.
The number of technology options available for reducing environmental impact are
highest early on in the life cycle and then decrease drastically. In contrast, costs associated
with resolving an environmental problem typically increase exponentially as the process
matures and the scale of equipment gets larger. There are technologies to control generic
classes of air pollutant emissions such as CO, Volate Organic Compounds (VOCs), NOx
or SOx. The specific choice of control technology, in most cases, is driven by the need
to meet regulatory compliance at the lowest cost. The most cost-effective strategy for a
given application, depends on a number of factors, including the nature of the pollutant, its
concentration, the flow rate of the exhaust, and regulation. The decision is based on:
Capability of treating a variety of wastes with varying constituents with minimal
pretreatment or characterization;
Secondary waste stream volumes that are significantly smaller than the original
waste stream volumes and which contain no toxic reaction byproducts;
11
POLLUTANTS AND POLLUTION SOURCES
1.4 References
1. Emissions of greenhouse gases in the United States: 1987-11992, DOE/EIA Report 0573, US Government
printing offices, Washington, DC, October, 1994.
2. http://www.eia.doe.gov/oiaf/1605/ggrpt/summary/index.html
3. Thiemens, M.H.&Trogler, W.C. Science, 1991, 251, 932.
4. Armor J.N., Catal. Today, 38 (1997) 163.
5. http//www.epa.gov
6. Air Pollution Control Engineering, de Nevers N., second Edition, 2000, Mc Graw Hill, New York.
7. Bell M.L., Davis D.L., Gouveia N., Borja-Aburto V.H., Cifuentes L.A., Environmental Research 100 (2006)
431.
8. Chow J.C., Watson J.G., Shah J.J., Kiang C.S., Loh C., Lev-On M., Lents J.M., Molina M.J., Molina L.T.,
Journal of Air & Waste Management Association 54 (2004) 1226.
9. Diem J.E., Ricketts C.E., Dean J.R., Climate Research 30 (2006) 201.
10. Gregg J.W., Jones C.G., Dawson T.E., Nature 424 (2003) 183.
11. Herndon S.C., Jayne J.T., Zahniser M.S., Worsnop D.R., Knighton B., Alwine E., Lamb B.K., Zavala M., Nelson
D.D., McManus J.B., Shorter J.H., Canagaratna M.R., Onasch T.B., Kolb C.E., Faraday Discuss. 130 (2005)
327.
12. Klumpp A., Ansel W., Klumpp G., Calatayud V., Garrec J.P., He S., Penuelas J., Ribas A., Ro-Poulsen H.,
Rasmussen S., Sanz M.J., Vergne P., Environ. Pollut. 139 (2006) 515.
13. Marshall J., Nature 437 (2005) 312.
14. Molina M.J., Molina L.T., Journal of the Air & Waste Management Association 54 (2004) 644.
15. Seigneur C., Aiche Journal 51 (2005) 356.
16. Pataki D.E., Alig R.J., Fung A.S., Golubiewski N.E., Kennedy C.A., McPherson E.G., Nowak D.J., Pouyat R.V.,
Lankao P.R., Global Change Biology 12 (2006) 2092.
17. Kaye J.P., Groffman P.M., Grimm N.B., Baker L.A., Pouyat R.V., Trends in Ecology & Evolution 21 (2006)
192.
18. Mitchell V.G., Diaper C., Water Sci. Technol. 52 (2005) 91.
19. Mitchell V.G., Diaper C., Environmental Modelling & Software 21 (2006) 129.
20. de Gouw J, Warneke C, Mass Spectrometry Reviews 26 (2007) 223.
12
AIR POLLUTION CONTROL TECHNOLOGIES
To monitor air pollution, trace substance must be measured at levels of ppm (part
per million) or ppb (part per billion) using high-sensitive analytical methods. The influence of
coexisting substances. Complicates both qualitative and quantitative determination. Most of
the analytical methods currently performed on gas components are chemical methods where
ambient air passes through an absorbent by bubbling to adsorb the desired component; the
component trapped by the adsorbent is quantitatively determined. In recent years, physical
methods have been developing by which air samples directly introduced into an analysis
unit are quantitatively determined.This chapter will briefly discuss systems most generally
used in continuous analyzers focusing on measurement methods for substances specified
in environmental quality standard relating to air pollution. For each major air pollutant, EPA,
defined a reference method, which is the test method that is considered the standard
against which other methods can be tested. There are equivalent methods, which have been
checked against the reference method and found to give similar results. The equivalent
methods are generally simplier, cheaper and easier to use than the reference methods and
therefore are commonly used by national and regional ambient monitoring agency.
13
TECHNIQUES FOR AIR POLLUTION MEASUREMENTS
2.5 Hydrocarbons
The thought that hydrocarbons other than methane (present in general ambient
air around 2 ppm) should be treated as non-methane hydrocarbons, namely, pollutants is
currently accepted generally. No environmental standards are established for non-methane
hydrocarbons, and guideline value is given. JIS specifies hydrogen flame ionization detection
(FID) method as continuous analyzer for hydrocarbons in ambient air.
14
AIR POLLUTION CONTROL TECHNOLOGIES
Chemiluminescence Spectroscopy
Chemiluminescence, like atomic emission spectroscopy (AES), uses quantitative
measurements of the optical emission from excited chemical species to determine analyses
concentration; however, unlike AES, chemiluminescence is usually emission from energized
molecules instead of simply excited atoms. The bands of light determined by this technique
emanate from molecular emissions and are therefore broader and more complex then bands
originating from atomic spectra. Furthermore, chemiluminescence can take place in either
the solution or gas phase, whereas AES is almost strictly as gas phase phenomenon.
15
TECHNIQUES FOR AIR POLLUTION MEASUREMENTS
The Clean Air Act, which was last amended in 1990, requires EPA to set National
Ambient Air Quality Standards for pollutants considered harmful to public health and the
environment. The Clean Air Act established two types of national air quality standards.
Primary standards set limits to protect public health, including the health of sensitive
populations such as asthmatics, children, and the elderly. Secondary standards set limits to
protect public welfare, including protection against decreased visibility, damage to animals,
crops, vegetation, and buildings (3-18).
The EPA Office of Air Quality Planning and Standards (OAQPS) has set National Ambient
Air Quality Standards for six principal pollutants, which are called criteria pollutants. They are
listed in Table 2.2. Units of measure for the standards are parts per million (ppm) by volume,
milligrams per cubic meter of air (mg/m3), and micrograms per cubic meter of air (g/m3).
16
AIR POLLUTION CONTROL TECHNOLOGIES
2.8 References
1. de Nevers N., Pollution Control Engineering, 2000, Mc Graw Hill, New York.
2. Cooper, H. B. B., Jr. and Rossano A.T. Jr., Source Testing for Air Pollution Control, Environmental Research
and Applications, Inc., Wilton, CT, 1971.
3. http://www.epa.gov/epahome/lawregs.htm and http://www.epa.gov/air/criteria.html
4. Pollution: Causes, Effects and Control, R. M. Harrison Ed., The Royal Society of Chemistry, Cambridge,
1996.
5. Diem J.E., Ricketts C.E., Dean J.R., Climate Research 30 (2006) 201.
6. Pataki D.E., Alig R.J., Fung A.S., Golubiewski N.E., Kennedy C.A., McPherson E.G., Nowak D.J., Pouyat R.V.,
Lankao P.R., Global Change Biology 12 (2006) 2092.
7. Kaye J.P., Groffman P.M., Grimm N.B., Baker L.A., Pouyat R.V., Trends in Ecology & Evolution 21 (2006)
192.
8. Mitchell V.G., Diaper C., Water Science and Technology 52 (2005) 91.
9. Mitchell V.G., Diaper C., Environmental Modelling & Software 21 (2006) 129.
10. Herndon S.C., Jayne J.T., Zahniser M.S., Worsnop D.R., Knighton B., Alwine E., Lamb B.K., Zavala M., Nelson
D.D., McManus J.B., Shorter J.H., Canagaratna M.R., Onasch T.B., Kolb C.E., Faraday Discuss. 130 (2005)
327.
11. M.L.Bell, D.L.Davis, N.Gouveia, V.H.Borja-Aburto, L.A.Cifuentes, Environmental Research 100 (2006) 431.
12. Chow J.C., Watson J.G., Shah J.J., Kiang C.S., Loh C., Lev-On M., Lents J.M., Molina M.J., Molina L.T.,
Journal of the Air & Waste Management Association 54 (2004) 1226.
13. Gregg J.W., Jones C.G., Dawson T.E., Nature 424 (2003) 183.
14. de Gouw J, Warneke C, Mass Spectrometry Reviews 26 (2007) 223.
15. Klumpp A., Ansel W., Klumpp G., Calatayud V., Garrec J.P., He S., Penuelas J., Ribas A., Ro-Poulsen H.,
Rasmussen S., MSanz.J., Vergne P., Environ Pollut. 139 (2006) 515.
16. Marshall J., Nature 437 (2005) 312.
17. Molina M.J., Molina L.T., Journal of the Air & Waste Management Association 54 (2004) 644.
18. Seigneur C., Aiche Journal 51 (2005) 356.
17
AIR POLLUTION CONTROL TECHNOLOGIES
NOx represent a family of seven compounds (Table 3.1). EPA regulates nitrogen
dioxide (NO2) as a surrogate for this family of compounds because it is the most prevalent
form of NOx in the atmosphere that is generated by anthropogenic (human) activities. NO2
is not only an important primar y air pollutant, but since it reacts in the atmosphere, it
is also a secondar y pollutant. NO2 react with water in the atmosphere to form acid rain.
Furthermore, NO2 can react with air in the presence of ultraviolet light (UV) to form ozone
and nitric oxide (NO). Then, NO can react with free radicals, created by UV irradiation of
VOC, forming PAN (1).
NO2 Nitrogen dioxide Red-brown gas, very water soluble, decomposes in water
N2O4 Dinitrogen tetroxide
N2O5 Dinitrogen pentoxide White solid, very water soluble, decomposes in water
Fuel NOx: Fuels that contain nitrogen (e.g., coal) create fuel NOx that results
from oxidation of the already-ionized nitrogen contained in the fuel.
Prompt NOx: Prompt NOx is formed from molecular nitrogen in the air combining
with fuel in fuel-rich conditions, which exist, to some extent, in all combustion. This nitrogen
then oxidizes along with the fuel and becomes NOx during combustion, just like fuel NOx.
19
NOX ABATEMENT TECHNOLOGIES
NOx abatement and control technology is a relatively complex issue. We shall try
to provide a structure of the main NOx pollution prevention and control technologies by first
giving the principles that are used. Then we shall describe the more successful pollution
prevention and emission control technologies and strategies. The Destruction or Removal
Efficiency (DRE) that each successful technology is capable of achieving, is one of the key
parameters for selecting the best available technology. Therefore effectiveness of pollution
control / reduction of NO and NO2 is also expressed in terms of relative DRE; i.e., comparison
of the NOx generated in the presence of a NOx reduction technology and in its absence.
In the case of combustion process, specific boiler types and combustion systems
will be considered along with the specific NOx technologies that can be applied. Notably,
many new combustion systems incorporate NOx prevention methods into their design and
significantly reduce NOx emissions compared to similar but older systems. As a result, the
use of DRE (even a relative DRE) for NOx may be inappropriate. In fact, the comparison
between actual NOx emissions from a new, well-designed system with those emitted by a
similar older system, equipped with the same NOX controlled technology, may be the best
way of evaluating how effectively a new combustion system minimizes NOx emissions.
The selection of the specific NOx abatement technology for a combustion system
should be based on the analysis of the required system modifications. Specifically, technical
and economic fusibility are primary restrictions. Therefore, in the process of identification of
the best applicable pollution prevention and emission control technologies, it must be first
consider the combustion system design.
The major types of combustion systems are shown in Table 3.2
Dry bottom boilers - wall-fired, front-fired or Opposed-fired pulverized coal, gas, or liquid
Wet bottom (slag tap) boilers - cyclone-type burners pulverized coal, gas, or liquid
Table 3.3 lists principles or methods that are used to reduce NOx;
20
AIR POLLUTION CONTROL TECHNOLOGIES
Table 3.3: NOx Control methods - (P) pollution prevention and (A) add-on technology *
Chemical Reduction of NOx (Method 3): This technique is based on the use of
a reducing agent, which react with NOx leading to N2 formation. Examples include Selective
Catalytic Reduction (SCR), which uses ammonia, Selective Non-Catalytic Reduction (SNCR)
21
NOX ABATEMENT TECHNOLOGIES
that use ammonia or urea, and Fuel Reburning (FR). Non-thermal plasma, in the presence of
a reducing agent, is an emerging and innovative technology.
Oxidation of NOx (Method 4): This technique is based on the possibility to fully
oxidize NOx to favor water to absorb them (i.e., it is based on the greater solubility of NOx at
higher N valence state). This is accomplished either by using a catalyst, injecting hydrogen
peroxide, creating ozone within the air flow, or injecting ozone into the air flow. Notably, non-
thermal plasma, in the absence of a reducing agent, can effectively oxidize NOx. A scrubber
must be added to the process to absorb N2 O5, avoiding emissions to the atmosphere.
Emissions of nitric acid can be controlled as well. In this case, nitric acid can be neutralized
by basic liquids in the scrubber. Notably, nitric acid can be collected and then sold (also as
a calcium or ammonia salt).
Existing NOx abatement technologies for stationary sources can be divided into two
categories, external combustion applications (e.g., boilers, furnaces and process heaters)
and internal combustion applications (e.g., stationary internal combustion engines and
turbines) (5-9). These categories can be further subdivided into pollution prevention (which
reduces NOx generation) and add-on control technologies, which reduces NOx emissions (flue
gas treatment). Each NOx abatement technology has different implementations, development
histories, and, therefore, commercial status. Selection of a suitable technology must occur
after an evaluation of the technical and economic feasibility of each NOx technology to
accurate be implemented on an existing system. The available options may be limited by
inability to adjust the existing combustion system.
22
AIR POLLUTION CONTROL TECHNOLOGIES
* Ref: R.M. Heck, R.J. Farrauto, Catalytic air pollution control: commercial technologies, van Nostrand Reinhold,
New York, p. 170, 1995.
Table 3.5: Representative problems of SCR and some of the possible solutions.
Problems Solution
The position of the SCR reactor in the process effluent of a thermal power plant
strongly influences the selection of the catalyst composition and its physical structure should
be used. For a high-ash, high-sulphur exhaust, there are three possible positions for the SCR
catalyst.
23
NOX ABATEMENT TECHNOLOGIES
Tail end location: This location provides the cleanest feed gas to the catalyst
since it has passed through an electrostatic precipitator and a flue gas desulfurizer. Extruded
homogenous zeolites or ceramic or metal substrates washcoated with V2O5/TiO2 or zeolites
can be used.
24
AIR POLLUTION CONTROL TECHNOLOGIES
Gas turbines use the Brayton Cycle with a burner to raise temperature of gas
after compression and before expansion through the turbine. Turbines mainly use reducing
peak temperature and reducing residence time (Methods 1 and 2) approaches to limit NOx
emissions. Because addition of particles to air flow entering the turbine would accelerate
erosion of turbine blades, sorbents (Method 6) could only be applied after the expansion in
the turbine. NOx reduction (Method 3) has been used to treat exhaust gases.
Table 3.6: Efficiency of NOx abatement technologies currently used for gas turbines
There has also been some success in reducing NOx concentrations when burning
biomass fuels in a boiler.
Table 3.6 reports the efficiency of the presents NOx abatement technologies used
for gas turbines.
It is worth noting that many turbine operators claim significant improvement of
air pollution control as a consequence of good combustion practices. They mostly refers to
reduction of particulate emissions (often focusing the attention to the reduction of the visible
fraction of PM). However, the NOx emission data are rarely reported. Cogeneration units use
a gas turbine to generate electricity and provide preheated combustion air for a boiler. Gas
turbine exhaust contains typically 10-15% oxygen and therefore it can be effectively used to
provide combustion air for a low-pressure boiler. This latter system can be used to provide
steam for another turbine, a process heater, a space heater, or a combination of these.
Notably, sorbent particles can be introduced into the exhaust gas turbine flow in order to
control NOx.
25
NOX ABATEMENT TECHNOLOGIES
reactor was developed for treatment of diesel exhaust. A plasma ignition system allows
greater freedom in the air-fuel ratio and the ignition timing of spark ignition engines. See
Table 3.7 for NOx technologies used for stationary internal combustion engines.
Table 3.7: Efficiency of NOx technologies currently used for stationary internal combustion engines
Solid Fuels
The combustion of a solid fuel, such as coal, is achieved by first allowing the
gasification of the volatile fraction of the fuel in a primary burner. A flow of air ensure
26
AIR POLLUTION CONTROL TECHNOLOGIES
the removal of the volatile fraction from char and its oxidation. The remaining solid needs
further combustion air to burn. This process provides supplementary heat, part of which
is used to volatilize additional fuel. The simple control of combustion temperature would
limit the amount of air which react with the char fraction. Therefore, the volatile fraction
must be oxidized in over-fire-air or a secondary stage of burner with its air control system.
The balance of combustion air must be carefully adjusted taking into consideration the
composition of fuel, the boiler loading, and transient loads. Fast dynamic air adjustments
are recommended.
Pulverized coal can be burned in a similar way to oil. The flame is usually well
defined and, depending on particle size of fuel, char may remain in suspension in flue gas
throughout burning. Normally, the volatile fraction burns in air together with the fine fuel
particles. However, if the particles of the fuel are too coarse, char will continue burning
on its trajectory after leaving the flame. At a certain point the combustion ends. The trade
jargon for this is unburned carbon (UBC), carbon in the ash (CIA), or loss of ignition
(LOI). These terms refer to carbon in char that does not burn along the trajectory. UBC can
be minimized by grinding particles finer and separate the various fractions of fuel particles
so that larger ones are returned to the roller mill or grinder.
Particles will become fly ash if they are small enough. UBC ranging from 0.5%
to 5% is considered acceptable. Therefore, the dimensions of the solid fuel particle is an
important parameter for the control of air pollution. Great attention must be dedicated to the
control of air to fuel stoichiometry and to the combustion temperature to minimize unburned
carbon in the ash. Notably, biomass represent an important solid fuel. However, in general,
it cannot be pulverized to small particles, but can burn to ash in a short time.
Even if particulate emissions from solid fuel are a serious problem, it exists a
set of technologies to control them (slag tap or ash pit, baghouse, and/or electrostatic
precipitator).
Liquid Fuels
Liquid fuels burn like the volatile fraction of solid fuel provided that the droplets are
small enough. Liquid fuels usually have less nitrogen content than solid fuels. Combustion
of liquids and gases can be controlled much more readily than that of solid fuel. Optimised
combustion of liquids can be performed without residual ash. The fuel-air ratio can be used
to control combustion temperature and therfore to minimize NOx generation. The flame can
be well defined and combustion is essentially completed within the flame.
Semi-solid Fuels
Semi-solid fuels are residuals from refineries. They are not clean burning fuels
like distillates and often are not even liquid at room temperature. Many impurities, typically
found in crude oil, are concentrated in semi-solid residual fuel. These fuels can contain
more nitrogen than coal, but usually contain less sulfur (28). Therefore, semi-solid fuels are
intermediate between coal and oil.
Gas Fuel
Natural gas is desulfurized before it is sent in a pipeline. Therefore, natural gas
has almost no sulfur, essentially no impurities, and no ash. The only thing that varies is heat
content per cubic meter. This variance is caused by natural gas producers supplementing
natural gas with propane, liquefied petroleum gas (butane), carbon monoxide, or other
gaseous fuel. As a result, air to fuel ratio must be carfully cheked to prevent changes in the
stoichiometric ratio.
27
NOX ABATEMENT TECHNOLOGIES
Fluidized bed combustion occurs in a bed of crushed coal that has air flowing
upward through it to make coal particles behave like a fluid. Boiler pipes can be either
submerged in the bed or exposed to the hot gases after they leave the bed. The fluidized bed
is temperature controlled (Method 1). The bed is also a chemically reducing region in which
available oxygen is consumed by carbon (Method 3) that reduces ionization of nitrogen.
Excess of air is injected (Method 2) over the fluidized bed to complete combustion of CO
and other burnables.In fluidized bed combustion it is possible to cold pulverized limestone
(Method 6) to control NOx emission. Notably, sulfur oxides, eventuallly produced during the
combustion can react with the limestone to form gypsum, a marketable product. Therefore,
gypsum must be separated from the ash. As a result, NOx generation can be essentially
limited to prompt NOx and fuel NOx .
The choice of technologies depends upon the type of combustion system, type
of boiler or other energy conversion device, and type of fuel used. Available technologies
will be narrowed by consideration of turndown ratio, stability of combustion, availability or
access to burners, air supply controls, fuel impurities, and cost among other factors. There
are many examples and here are a few of them. Selective catalytic reduction of NOx to
N2 can be followed by selective oxidation of sulfur dioxide to sulfur trioxide. Then sulfuric
acid is formed followed by scrubbing sulfuric acid from the flue gas (29). LNB can be used
in conjunction with SCR or SNCR to achieve a greater overall DRE than any of these can
achieve alone. Water/steam injection can be used with SCR to achieve a DRE greater than
SCR can achieve alone. Fuel reburning and SCR can be used together as well as separately,
to get the maximum NOx reduction (30).
28
AIR POLLUTION CONTROL TECHNOLOGIES
No. 2
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Burners out of service (BOOS)
Application: All fuels, multiple burners for BOOS, used for dry bottom wall-fired, front-
fired or opposed-fired boilers.
Description: Staged combustion: multiple-burner equipment can have part of an array of
burners with some burners out of service (not feeding fuel, but supplying
air or flue gas). This allows the burners around them to supply fuel and
air to air or flue gas flowing from the BOOS. The result is a multi stage
combustion process by stages with temperatures always lower than when
all burners are in service. Therrefore, thermal NOx emission are lower. The
degree of NOx reduction depends upon the spatial relationship betwen the
BOOS and the other burners.
Advantages: Low cost, no capital cost for BOOS.
Disadvantages: Higher air flow for CO
Ref./Source: Methods for Reducing NOx Emissions, C. Latta, Roy F. Weston Inc., Plant
Engineering, September 1998.
No. 3
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Over fire air (OFA)
Application: All fuels, used for dry bottom wall-fired, front-fired or opposed-fired boilers,
dry bottom tangentially fired boilers, wet bottom (slag tap boilers), fluidized
bed combustion, stokers with traveling grates and stokers with spread
grates.
Description: The OFA completes the combustion. When the primary combustion is
carried out with a fuel-rich mixture. The temperature i keept low by working
under off-stoichiometric combustion. The unburned fuel is fully oxidised in
the OFA.
Advantages: Low operating cost.
Disadvantages: High capital cost.
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NOX ABATEMENT TECHNOLOGIES
No. 4
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Low NOx burner (LNB)
Application: All fuels, used for dry bottom wall-fired, front-fired or opposed-fired boilers
and stokers with spread grates.
Description: A LNB provides a stable flame that has several different zones. For example,
the first zone can be primary combustion. The second zone can be Fuel
Reburning (FR) with fuel added to chemically reduce NOx. The third zone can
be the final combustion in low excess air to limit the temperature. There are
many variations on the LNB design. The LNB has produced up to 80% DRE.
This can be one of the less expensive pollution prevention technologies
with high DRE.
Advantages: Low operating cost, compatible FGR.
Disadvantages: Moderately high capital cost.
Ref./Source: Gas Reburning for High Efficiency NOx Control Boiler Durability Assessment,
B. A. Folsom, T. Sommer, D. Engelhardt, and S. Freedman, 96-RP139.04, Air
& Waste Management Assn. Regulatory Developments in NOx Controls for
Utility Boilers, C. Harrison, 96-RP139.03, Air & Waste Management Assn.
Overview of NOx Emission Control for Utility Boilers, J. E. Staudt, Proceedings
of the American Power Conference, 1993.
Select the Right NOx Control Technology, S. Wood, Chemical Engineering
Progress, January 1994.
No. 5
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Flue gas recirculation (FGR)
Application: All fuels, low nitrogen fuel, used for dry bottom wall-fired, front-fired or
opposed-fired boilers, bottom tangentially fired boilers, wet bottom (slag
tap) boilers. Fluidized bed combustion and stokers with traveling grates.
Description: < 30% flue gas recirculated with air, decreasing temperature: decreasing
recirculation of cooled flue gas reduces temperature by diluting the oxygen
content of combustion air and by causing heat to be diluted in a greater
mass of flue gas. Heat in the flue gas can be recovered by a heat exchanger.
This reduction of temperature lowers the NOx concentration. If combustion
temperature is held down to below 760 C, thermal NOx formation can be
negligible.
Advantages: High NOx reduction, potential for low nitrogen fuels.
Disadvantages: Moderately high capital cost. And operating cost, affects heat transfer and
system pressures.
Ref./Source: Fossil Fuel Combustion, A Source Book, W. Bartok and A. Sarofim, Wiley-
Interscience, John Wiley & Sons.
No. 6
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Water or steam injection
Application: All fuels, low nitrogen fuel, used for dry bottom wall-fired, front-fired or
opposed-fired boilers, bottom tangentially fired boilers, wet bottom (slag
tap) boilers and stokers with traveling grates.
Description: Injection of water or steam causes the stoichiometry of the mixture to be
changed and adds steam modifics the reaction stoichiometry and reduces
the working temperature. Both of these actions leads to lower thermal NOx
emissions.
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AIR POLLUTION CONTROL TECHNOLOGIES
No. 7
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Reduced air preheat
Application: All fuels, low nitrogen fuel, used for dry bottom wall-fired, front-fired or
opposed-fired boilers, bottom tangentially fired boilers, wet bottom (slag
tap) boilers, fluidized bed combustion, stokers with traveling grates and
stokers with spread grates
Description: Air is usually preheated to cool the flue gases, reduce the heat losses,
and gain efficiency. However, this can raise the temperature of combustion
favoring NOx formation. By reducing air preheat, the combustion temperature
is lowered and NOx formation is reduced. This can lower efficiency, but can
limit NOx generation.
Advantages: High NOx reduction potential.
Disadvantages: Significant efficiency loss.
No. 8
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Fuel reburning (FR)
Application: All fuels, pulverized solid, used for bottom tangentially fired boilers, wet
bottom (slag tap) boilers, fluidized bed combustion, stokers with traveling
grates and stokers with spread grates.
Description: Recirculation of cooled flue gas with added fuel (this can be natural gas,
pulverized coal, or even oil spray) causes heat dilution, similar to that
abserved in the case of FGR, and a reduction of the primary combustion
temperature. When the FR is added in a secondary combustion stage, the
presence of fuel chemically reduces newly generated NOx to molecular
nitrogen. The fuel is only partially consumed in the reduction NOx of and
its burning is completed in a subseguent stage using either combustion
air nozzles or over-fire-air. This technique has been demonstrated to be
effective with residence times from 0.2 seconds to 1.2 seconds and has
achieved up to 76% DRE.
Advantages: Moderate cost, moderate NOx removal.
Disadvantages: Longer residence times.
Ref./Source: Gas Reburning for High Efficiency NOx Control Boiler Durability Assessment,
B. A. Folsom, T. Sommer, D. Engelhardt, and S. Freedman, 96-RP139.04,
Air & Waste Management Assn.
No. 9
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Combustion optimization
Application: Gas liquid fuel, used for dry bottom wall-fired, front-fired or opposed-fired
boilers, stokers with traveling grates and stokers with spread grates.
Description: Combustion optimization refers to the active control of combustion. In a
natural gas fired boiler, by decreasing combustion efficiency from 100% to
99%, NOx generation dropped to a much more acceptable level. For coal-fired
boilers a 20% to 60% reduction in NOx has been experienced. These active
combustion control measures seek to find optimum combustion efficiency
and to control combustion (and hence emissions) at that efficiency. Another
approach uses a neural network computer program to find the optimum
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NOX ABATEMENT TECHNOLOGIES
No. 10
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Air staging
Application: All fuels, used for dry bottom wall-fired, front-fired or opposed-fired boilers,
dry bottom tangentially fired boilers, wet bottom (slag tap) boilers, stokers
with traveling grates and stokers with spread grates.
Description: Combustion air is divided into two streams. The first stream is mixed with
fuel in a ratio that produces a reduced flame. The second stream is injected
downstream of the flame and makes the net ratio slightly rich air in DRE up
to 99% have been reported.
Advantages: Reduce peak combustion temperature.
Disadvantages: Extend combustion to a longer residence time at lower temperature
Ref./Source Maximum Achievable Control Technology for NOx Emissions from Thermal
Oxidation, P.Nutcher and D. Lewandowski, 94-WA74A.03, Air and Waste
Management Association, Annual Meeting, Cincinnati, OH, June 19-24 1994.
No. 11
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Fuel staging
Application: All fuels, used for dry bottom wall-fired, front-fired or opposed-fired boilers,
dry bottom tangentially fired boilers, wet bottom (slag tap) boilers, stokers
with traveling grates and stokers with spread grates.
Description: This Technologyis is based on the staging of combustion. Fuel is divided
into two streams. The first stream feeds primary combustion that operates
in a reducing fuel to air ratio. The second stream is injected downstream
of primary combustion, causing the net fuel to air ratio to be only slightly
oxidizing. Excess fuel in primary combustion dilutes heat to reduce
temperature. The second stream oxidizes the fuel while reducing the NOx to
N2. This is reported to achieve a 50% DRE.
Advantages: Reduce peak combustion temperature.
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AIR POLLUTION CONTROL TECHNOLOGIES
No. 12
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Oxygen instead of air
Application: All fuels, used for wet bottom (slag tap) boilers.
Description: Use oxygen to oxidize fuel: an example of this is a cyclone burner where the
flame is short and intense. This technique has reduced NOx by up to 20% in
burners using conventional fuel. This technique also is usable with low-NOx
burners to prevent the prompt NOx from being formed.
Advantages: Moderate to high cost, intense combustion.
Disadvantages: Eliminates only prompt NOx, furnace alteration.
Ref./Source: Reducing NOx Emissions, B. Chambers, Glass Industry, May 1993.
Nitrogen Oxides Control Technology Fact Book, Leslie L. Sloss, Noyes Data
Corp., 1992.
No. 13
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Inject oxidant
Application: All fuels, used for dry bottom wall-fired, front-fired or opposed-fired boilers,
stokers with traveling grates and stokers with spreader grates.
Description: Chemical oxidant injected in flow: The oxidation of nitrogen to its higher
valence states makes NOx soluble in water. Gas absorbers can be effective
used. Many oxidants have been injected into the airflow such as ozone, ion-
ized oxygen, or hydrogen peroxide. Non-thermal plasma generating oxygen
ions within the air flow have been also used. Water, hydrogen peroxide, or
an alkaline fluid can effectively absorb nitric acid.
Advantages: Moderate cost.
Disadvantages: Nitric acid removal.
No. 14
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Catalytic combustion
Application: Gas liquid fuels.
Description: Catalytic combustion at occurs lower temperature with respect to the
uncatalysed reach an the resulting reduction in the working temperature
leads to a significant NOx reduction. This technique is not used often
because it is very load sensitive. However, where it is used, catalytic
combustion can achieve less than 1-ppm concentration of NOx in the flue gas.
Advantages: Lowest possible NOx emissions.
Disadvantages: Very high capital cost, high operating cost, catalyst deactivation.
Ref./Source: Low-Emission Gas Turbines Using Catalytic Combustion, S. Vatcha, Energy
Conversion Management, Vol. 38 No. 10-13, pp. 1327-1334.
33
NOX ABATEMENT TECHNOLOGIES
No. 15
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Ultra-low nitrogen fuels
Application: All ultra-low nitrogen fuels, dry bottom wall-fired, front-fired or opposed-fired
boilers, dry bottom tangentially fired boilers, wet bottom (slag tap) boilers,
fluidized bed combustion, stokers with traveling grates and stokers with
spreader grates.
Description: Uses low-nitrogen fuel: These fuels can avoid NOx that results from nitrogen
contained in conventional fuels. Up to 70% reduction in NOx emissions
has been reported. Now there are ultra-low-nitrogen liquid fuel oils. These
oils contain 15-20 times less nitrogen than standard fuel oil. This oil is
now commercially available and competitively priced. Ultra-low-nitrogen oil
is most frequently used in Southern California where the air pollution is
particularly a problem. Natural gas can be considered a low-nitrogen fuel.
Coke (the quenched char from coal) can also be an ultra-low-nitrogen fuel
because nitrogen in the volatile fraction of the coal is removed in making
coke.
Advantages: Eliminates fuel NOx, No capital cost.
Disadvantages: Slight rise in operating cost.
Ref./Source: www.cleaver-brooks.com/Emissions1.html
No. 16
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Non-thermal plasma reactor (NTPR)
Application: Dry bottom wall-fired, front-fired or opposed-fired boilers, dry bottom
tangentially fired boilers, wet bottom (slag tap) boilers, fluidized bed
combustion, stokers with traveling grates and stokers with spreader grates.
Description: Reducing agent ionized or oxidant created in flow: Using methane and
hexane as reducing agents, non-thermal plasma has been shown to
remove NOx in a laboratory setting with a reactor duct only 2 feet long. A
transient high voltage that created non-thermal plasma ionized the reducing
agents. The ionized reducing agents reacted with NOx and achieved a 94%
DRE. There are indications that an even higher DRE can be achieved. A
successful commercial vendor uses ammonia as a reducing agent to react
with NOx in an electron beam generated plasma. Such a short reactor can
meet available space requirements for virtually any plant. The non-thermal
plasma reactor could also be used without reducing agent to generate
ozone and use that ozone to raise the valence of nitrogen for subsequent
absorption as nitric acid.
Advantages: Moderate cost, easy siting, high NOx removal.
Disadvantages: Fouling possible, ozone emission possible.
No. 17
Classification of technology: Air Pollution (ADD-ON Control)
Name of technology/technique: Selective catalytic reduction (SCR)
Application: Dry bottom wall-fired, front-fired or opposed-fired boilers, dry bottom
tangentially fired boilers, wet bottom (slag tap) boilers, fluidized bed
combustion, stokers with traveling grates and stokers with spreader grates.
Description: Catalyst located in the air flow, promotes reaction between ammonia and
NOx: SCR uses a catalyst to react injected ammonia to chemically reduce
NOx. It can achieve up to a 94% DRE and is one of the most effective
NOx abatement techniques. However, this technology has a high initial
34
AIR POLLUTION CONTROL TECHNOLOGIES
cost. In addition, catalysts have a finite life in flue gas and some ammonia
slips through without being reacted. SCR can used precious metal
based catalysts or base metal and zeolite based catalysts. However, the
base metal and zeolite catalysts operate at higher temperatures then the
precious metal catalysts.
Advantages: High NOx removal
Disadvantages: Very high capital cost, high operating cost, catalyst siting, increased
Pressure drop possible water wash required.
Ref./Source: Selective Catalytic Reduction Control of NOx Emissions, SCR Committee of
Institute of Clean Air Companies, November 1997.
No. 18
Classification of technology: Air Pollution (ADD-ON Control)
Name of technology/technique: Selective non-catalytic reduction (SNCR)
Application: Dry bottom wall-fired, front-fired or opposed-fired boilers, dry bottom
tangentially fired boilers, wet bottom (slag tap) boilers, fluidized bed
combustion, stokers with traveling grates, stokers with spreader grates.
Description: In SNCR ammonia or urea is injected within a boiler or in ducts in a region
where temperature is between 900 oC and 1100 oC. This technology is
based on temperature ionizing the ammonia or urea instead of using a
catalyst or non-thermal plasma. It is necessary to control the working
temperature windows to avoid ammonia slip or high NOx emissions. The
temperature window is different for urea and ammonia. Reduction of the
NOx by SNCR can have up to a 70% DRE.
Advantages: Using urea-low capital cost moderate NOx removal, Non-toxic chemical.
Using ammonia: low operating cost, Moderate NOx removal.
Disadvantages: Temperature dependent NOx reduction, moderately high capital cost, area
or ammonia storage, handling, injection system.
Ref./Source: Nitrogen Oxides Control Technology Fact Book, Leslie L. Sloss, Noyes Data
Corp., 1992.
Selective Non-Catalytic Reduction for Controlling NOx Emissions, SNCR
Committee of Institute of Clean Air Companies, October 1997
www.cleaver-brooks.com/Emissions1.html.
No. 19
Classification of technology: Air Pollution (ADD-ON Control)
Name of technology/technique: Sorption-both! adsorption and absorption
Application: Dry bottom wall-fired, front-fired or opposed-fired boilers, dry bottom
tangentially fired boilers, wet bottom (slag tap) boilers, fluidized bed
combustion, stokers with traveling grates, stokers with spreader grates. 1)
Use sorbents in combustion, 2) duct to baghouse, 3) due to electrostatic
precipitator.
Description: Use a chemical to absorb NOx or an adsorber to hold it: Several methods are
used to inject and remove adsorbent or absorbent. One-method sprays dry
powdered limestone into the flue gas. The limestone then reacts with both
sulfuric acid and nitric acid. There is a spray dryer approach that consist of
spraying slurry of powdered limestone and aqueous ammonia into the flue
gas. The limestone preferentially reacts with the sulfur while the ammonia
preferentially reacts with the NOx. In-duct injection of dry sorbents is another
example of this technique and can reduce pollutants in three stages: (1) in
the combustion chamber, (2) in the flue gas duct leading to the baghouse,
and (3) in the flue gas duct leading to the electrostatic precipitator. The by
35
NOX ABATEMENT TECHNOLOGIES
No. 20
Classification of technology: Air Pollution (Add-on Control)
Name of technology/technique: Selective catalytic reduction
Application: Internal Combustion
Description: As with boilers, SCR can be used to obtain up to a 90% DRE of NOx. When
used with a LNB or steam/water injection, NOx can be reduced to 5-10
ppm. With compression ignition engines, zeolite catalysts achieve a DRE of
90+%, while base-metal catalysts can achieve a 80% to 90% DRE.
Advantages: 90% efficiency can be achieved.
Disadvantages: Operating cost.
Ref./Source: Low-Emission Gas Turbines Using Catalytic Combustion, S. Vatcha, Energy
Conversion Management, Vol. 38 No. 10-13, pp. 1327-1334.
Alternative Control Techniques Document -- NOx Emissions from Stationary
Reciprocating Internal Combustion Engines. EPA-453/R-93-032, July 1993.
No. 21
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Steam injection
Application: Reduce the concentration of NOx discharged by gas turbine from
200ppm to 6ppm in accordance with the pollution prevention. Chemical;
Petrochemical.
Description: Steam injection was provided in the combustion chamber of the gas turbine
and the flue gas denigration system was installed in the exhaust gas boiler
as a measure for reducing the amount of NOx discharge that was increasing
in line with the installation of gas turbine equipment.
1. Suppression of NOx generation by injecting steam into the gas turbine.
Fuel/Steam = 1/1 ~ 1/1.2
2. Denigration by the ammonia catalytic reduction method.
Catalyst : 4NO + 4NH3 + O2 4N2 + 6H2O
Catalyst : NO + NO2 + 2NH3 2N2 + 3H2O
Implementing company: Ishihara Sangyo Co., Ltd., Yokkaichi Plant.
No. 22
Classification of technology: Air Pollution (Add on Control)
Name of technology/technique: Combined techniques
Application:. Reduce NOx, SOx and soot in flue gas discharged from chimney stacks.
Description: Flue gas is passed between multiple electrodes charged with high voltage
where soot particles in the flue gas are collected by charging the particles
36
AIR POLLUTION CONTROL TECHNOLOGIES
negatively and attracting them to the positive electrode. The particles adhering
to the electrode are removed mechanically by tapping with a hammer.
1. Denigration (Dry ammonia catalytic reduction method)
4NO + 4NH3 + O2 4N2 + 6H2O
2. Desulphurization (magnesium hydroxide method)
SO2 + Mg (OH)2 MgSO3 + H2O
2MgSO3 + O2 2MgSO4
3. Soot ( Electric precipitator )
Advantages: High Efficiency Denigration (80%) Desulphurization (99%) Soot removed
(96%)
Implementing company: Mitsubishi Chemical Co., Ltd.
No. 23
Classification of technology: Air Pollution (Add on Control)
Name of technology/technique: Removal of exhaust NOx by ammonia catalytic reduction
method (SCR)
Application: Chemicals, petrochemical. As a result of changing the boiler fuel from heavy
oil to petroleum coke, the concentration of NOx in the exhaust gas increased
to the nitrogen content in the fuel. Using the dry ammonia contact reduction
method therefore carried out removal of NOx.
Description: Use a high performance honeycomb type catalyst.
4NO + 4NH3 + O2 4N2 + 6H2O
Advantages: Removal of 85% of NOx generated in the boiler furnace in line with witching
of its fuel.
Implementing company: Tosoh Company, Ltd. Yokkaichi Plant
No. 24
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Low NOx combustion technology
Preface: Low NOx combustion technologies include the following technologies.
Low NOx burner (aerodynamically controlled tope and split flame type)
Combustion modification such as air staging and flue gas mixing
IFNR (In-Furnace NOx Reduction) combustion.
Application: Boilers for the utility thermal power plant and Boilers for industrial-owned
thermal power plant.
Description: 1. Low NOx Burner
Low NOx type burners control the strength of the fuel mixing with the
combustion air and realize fuel rich region locally in the process firing fuels.
The split flame type burner is of off-stoichiometric firing type and is only
adopted in firing fuel oils. DF (Dual Flow) type low NOx burner is of an
aerodynamically mixing control type and is used for all fuels.
2. Combustion Modification
The air staging and the flue gas mixing technologies are adopted to reduce
NOx emissions in the combustion modification. On staged firing, a part of
combustion air is branched from the stream to the burner firing system, and
introduced to the furnace through OAPs (Overfire Air Ports), distributed at
the down stream of the burner region. Consequently, fuel rich firing can be
realized by air staging and NOx formation can be therefore reduced. The
flue gas mixing technology gives the decrease of the flame temperature.
Lowering flame temperature, while fuel-NOx, originated by fuel-bound
nitrogen, is insensitive to flame temperature, significantly reduces thermal-
37
NOX ABATEMENT TECHNOLOGIES
No. 25
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Combustion improvement system
Description: Combustion air is mixed with portion of flue gas to slow combustion,
avoiding local rise in temperature and thereby reducing NOx generation.
Part of the fuel is used as reducing agent to reduce NO generated in the
combustion chamber, thereby reducing NOx generation.
Advantages: Established and widely employed technology
Capacity: NOx reduction efficiency: Approx. 20 - 50% by combination of these
methods
Application: Fossil power stations etc. (The Kansai Electric Power Co., Inc.)
Source/Ref : http://nett21.unep.or.jp/CTT_DATA/Contents4.html
No. 26
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: Low NOx burner for industrial furnace
Description: Principle of Low NOx Burner.
Slow combustion has been adapted as a heating efficiency measure by
suppression of mixing of fuel and air during the initial stage of combustion.
The direction of fuel injection is at an angle to the air stream axis, and the
mixing of fuel and air in the primary combustion zone is limited. Therefore
a local high temperature region cannot develop. Fuel, which is not burned
in this zone gradually, mixes with air not used in the initial stages and
38
AIR POLLUTION CONTROL TECHNOLOGIES
No. 27
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: 3-Stage low NOx combustion system
Description: High performance, super low NOx system, a combination of ordinary
combustion type burner and HITACHI ZOSENs patented 3-stage combustion
type low NOx system.
Advantages: 1. In case of 3-stage combustion system, reducing combustion is limited
only to the secondary combustion zone, so that reducing atmosphere space
is very narrow. Furthermore, since measure are taken so that combustion
gas with a strong reducing capability does not directly strike the water wall,
adverse effects from such things as reducing corrosion and slagging on
the heating surfaces inside the furnace due to reducing atmosphere, even
in the case of super low NOx combustion, are extremely small compared
to other NOx reduction systems such as OFA combustion system, which
expose a large part of the furnace inside to reducing atmosphere.
2. Normal oxidizing combustion is performed in the primary combustion
zone (main combustion zone) where most of the fuel burns and combustion
efficiency is very high. The unburnt part from the secondary fuel in the
secondary combustion zone (reducing combustion zone) is burnt in the
tertiary combustion zone (combustion completion zone). Consequently,
combustion efficiency in a 3-stage type low NOx boiler is as high as in
ordinary boilers without NOx reduction.
3. Due to the features mentioned above, the NOx value in a 3-stage
combustion type low NOx boiler can reach to 100 ppm or less with ordinary
bituminous coal. The NOx value decreases if the combustion gas remains
longer in the secondary combustion zone (reducing combustion zone). The
dimensionless residence time of combustion gas in the reducing zone
based on the specified time, the time the combustion gas stays in the
reducing zone of a specified boiler. The heavy line in the figure indicates the
guaranteed NOx value (with standard design) with ordinary bituminous coal.
From this, the dimensionless reducing time will be set at about 1.1 for a
boiler with a guaranteed NOx of 100 ppm. As just explained, this low NOx
combustion system consists of three stages, that is, primary, secondary
and tertiary stage, and the following is an explanation of each stage.
Primary Combustion Zone
In the normal combustion type non-low NOx burner, normal oxidizing
combustion with an air ratio of 1.0 or over is performed. The amount of
39
NOX ABATEMENT TECHNOLOGIES
fuel here is 65-75% of total boiler fuel and the flame is raised to a very
high temperature and a high combustion efficiency is obtained because the
minimum combustion air needed for complete combustion is applied and
also flame length is adjusted to be as short as possible. Consequently,
the flame in this zone is a bright golden color and good combustion can
be confirmed at a glance. Generation of NOx in the primary combustion
area is not controlled at all and the aim is only to reach 100% combustion
efficiency.
Secondary Combustion Zone
25-35% of the fuel for the boiler is blown in from the secondary fuel port.
This secondary fuel includes air for transport but any other air is strictly
excluded to improve its performance as a denitration agent. The denitration
reaction is as follows:
1. Since the secondary fuel port is located just above the burner, secondary
fuel is heated intensely by the burner flame and hydrogen (H2), hydrocarbon
(CmHn), carbon monoxide (CO), charcoal (C), etc. are formed as very active
reducing components.
2. The atmosphere in the center of the secondary combustion zone has very
high reaction ability because the air ratio is about 0.7-0.8 of the theoretical
air ratio.
3. The atmosphere temperature in the secondary combustion zone is a
very ideal at about 1400 C so that the chemical reaction of the reducing
components and NOx from the primary combustion zone occurs intensely.
4. The secondary fuel is injected in stripes in the horizontal cross section
of the furnace and there are plenty of secondary fuel ports for complete
mixing of the secondary fuel and the combustion gas from the primary
combustion zone.
5. In the course of the process mentioned above, most of NOx in the
primary combustion gas is instantly reduced to inactive N2 by hydrogen,
hydrocarbon, carbon monoxide, charcoal, etc. which are formed from the
secondary fuel.
6. Since combustion in the secondary combustion zone takes place
with insufficient air, there is almost no new generation of NOx while a
sizable amount of unburnt components remains from the secondary fuel.
Consequently, the longer the gas remains in the secondary combustion
zone, the lower NOx becomes.
Tertiary Combustion zone
30-40% of all the air used for combustion is injected from the OFA port and
the unburnt components from the secondary combustion zone are burnt.
The OFA port is positioned so that it is in the ideal gas temperature zone
from the viewpoint of improved combustion of the unburnt components and
for control of new generation of thermal NOx . OFA is injected in stripes on
the horizontal cross section of the furnace, and there are a number of OFA
ports so the OFA is completely mixed with the combustion gas from the
secondary combustion zone. In the tertiary combustion zone, combustion
efficiency increases in accordance with the increase of the space between
the OFA ports and the furnace exit. However, this increases the size and
weight of the boiler, so the size of this space is determined from the total
cost including facility costs and running cost of the boiler.
Implementing company: HITACHI ZOSEN CORPORATION
Ref./Source: http://nett21.unep.or.jp/CTT_DATA/Contents4.html
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AIR POLLUTION CONTROL TECHNOLOGIES
No. 28
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: High-temperature combustion catalyst
Application: The technology has not been commercialized, but following applications
are expected. Gas turbine, Boiler, Gas-heater, Byproduct gas combustor,
Off-gas treatment, Deodorizer
Description: In order to reduce NOx emission, integrated combustion techniques such as
lean-burn combustion and water injection have been developed. However,
it is difficult to reduce NOx emission to ultra-low concentration, because
thermal NOx is formed by thermo-chemical reaction between nitrogen and
oxygen in air. The NOx formation reaction strongly depends on temperature,
thermal NOx is extensively produced in high temperature zone over than
1500 deg. C inside a combustion flame.
Catalyst combustion is one kind of flame-less combustion in which fuel
is oxidized perfectly without high temperature zone and which scarcely
produces thermal NOx .
Catalyst is made of Mn-substituted hexa-aluminate (Sr0.8La0.2MnAl11Ol9-a
Catalyst powder is extruded to a honeycomb shape and sintered at high
temperature. Honeycomb shape with 300cells/inch2 is used for natural gas
combustor. In gas-turbine combustor, three types of catalyst honeycomb are
combined. At the top of the catalyst bed, conventional noble metal catalyst
honeycombs, which have a high reaction activity under low temperature, is
located. Two types of hexa-aluminate honeycombs are used in the middle
and bottom parts. Fuel is mixed with air, heated by pre-burner to around
450 C, and oxidized smoothly in the catalyst bed in which temperature
rises continuously to around 1200 C.
It was known that catalyst combustion was effective for low NOx combustion,
but catalyst having high temperature durability over than 1000 C was
not developed. Mn-hexaaluminate is the only one catalyst which can be
stably used over than 1000 C. 8000 hours of catalyst life at 1300 C
is confirmed by atmospheric combustion test, and 1000 hours of stable
operation is also confirmed at high pressure combustion test. When
large diameter honeycomb is used for a large-scale combustor, formation
of cracks on the honeycomb caused by thermal stress is an important
problem. Segmentation system, which is effective in reducing thermal
stress, is developed, and optimum shapes of honeycomb segments are
designed with FEM simulation model.
Efficiency: A test device for the 150kW prototype catalytic combustion turbine was
prepared. In the test, turbine pressure ratio, air flow rate and combustor
inlet air temperature were 8.5, 1.8 kg/s and 350 C, respectively, and
both combustion efficiency higher than 99% and NOx emissions less than
40 ppm were attained after 215 hours of continuous operation. In addition
no visible cracks was observed in either the catalyst honeycomb or the
catalyst holder after the test.
Implementing company: KOBE STEEL, LTD.
Ref./Source: http://nett21.unep.or.jp/CTT_DATA/Contents4.html
No. 29
Classification of technology: Air Pollution (Prevention Method)
Name of technology/technique: The SCR DENOX process-haldortopsoe
Applications: The SCR process can be applied in various applications and is especially
dedicated to high NOx -removal efficiencies.
41
NOX ABATEMENT TECHNOLOGIES
Topsoe has applied its SCR DENOx process to applications such as:
Coal fired Boilers, Oil fired Boilers, Lignite fired Boilers, Pet Coke fired
Boilers, Gas fired Boilers, Diesel Engines, Gas Engines, Gas Turbines,
Waste Incinerators
Description: The SCR technology was developed in Japan in the 1970s and first
implemented at fossil fuel-based power plants in major Japan cities, where
the level of photochemical smog had reached unacceptable levels. Since
then, the technology has gradually spread to the rest of the word where it
has found such wide spread use that it today is the most widely applied
technique for reducing NOx in flue gases and exhaust gases. Selective
catalytic reduction, SCR, is considered the most efficient commercially
proven method of removing nitrogen oxides (NOx ) from off-gases. In the
SCR DeNOx process the nitrogen oxides (NO2 and NO) are reacted with
ammonia (NH3) over a catalyst to form harmless and naturally occurring
nitrogen (N2) and water vapor (H2O):
4 NO + 4 NH3 + O2 4 N2 + 6 H2O
6 NO2 + 8 NH3 7 N2 + 12 H2O
The SCR process basically consists of a catalytic reactor and an ammonia
storage and injection system. The reducing agent can be either liquid,
water-free ammonia under pressure or an aqueous ammonia solution at
atmospheric pressure. A solution of urea can be used as well. In case liquid
ammonia is used, the ammonia is volatilized and subsequently diluted with
air before being injected into the exhaust gas duct.
Chemicals Plants
Each application has its own characteristics and different demands to the
DeNOx catalyst and technology. For example, in the high-dust process for
coal-fired boilers, the SCR reactor is placed immediately after the boiler
and upstream of the electrostatic precipitator. The catalyst is exposed to
heavily dust-laden flue gas and must be resistant to erosion and possible
poisons in the fly ash. The SCR process can, in principle, be applied on any
flue gas containing NOx and oxygen.
Topsoe SCR DENOX Catalysts DNX Series.
Topsoes DNX-series of catalysts comprises SCR DENOX catalysts, tailored
to suit a comprehensive range of process requirements.
The DNX catalysts feature: High NOx removal activity, Low pressure drop,
Low SO2 oxidation rate and Excellent durability
DNX catalysts are based on a corrugated, fiber reinforced titanium dioxide
(TiO2) carrier. The carrier is impregnated with the active components:
vanadium pentoxide (V2O5) and tungsten trioxide (WO3). The catalyst is
shaped to a monolithic structure with a large number of parallel channels.
Efficiency: The unique catalyst design provides a highly porous structure with a large
surface area and an ensuing large number of active sites. The high and
well-defined porosity is the key to:
- A high NOx removal level with minimum ammonia slip
- A low activity towards SO2 oxidation, minimizing the risk of fouling
downstream equipment
- A high poison resistance ensuring a long and stable service life
- A substantially lower weight than for conventional plate or extruded
catalysts, allowing a fast response to changes in operation
To ensure optimum performance in any type of operating environment, the
DNX catalysts are available in a wide range of channel sizes and chemical
formulations.
42
AIR POLLUTION CONTROL TECHNOLOGIES
Ref./Source: www.haldortopsoe.com
No. 30
Classification of technology: Air Pollution
Name of technology/technique: SNOX process-haldortopsoe
The SNOX process is an innovative process, which removes sulphur and
nitrogen oxides from flue gases, recovers the sulphur oxides as concentrated
sulphuric acid and reduces the nitrogen oxides to free nitrogen. The process
is based on catalytic reactions and does not consume water, absorbents or
chemicals, except for ammonia for the reduction of nitrogen oxides. Further
it does not generate secondary sources of pollution such as wastewater,
slurries, or solids, and it does not release CO2 to the atmosphere. Process
heat and the heat content of the flue gas down to a temperature of 100C
are recovered and utilized in the boiler to increase steam production.
Contrary to other flue gas cleaning processes the operating costs decrease
with increasing sulphur content in the fuel. Thus, with the SNOx process
high-sulphur fuels can be utilized in an environmentally acceptable and
economically attractive way.
Furthermore, the SNOx process accepts flue gas with high content of SO3.
Apart from being an efficient and cost effective tool in the abatement of
air pollution, the SNOx process meets future regulations and standards for
solid waste management, water pollution, and resource conservation.
Applications: The process is applicable to flue gases from power stations, industrial and
institutional boilers as well as industrial off-gases containing sulphur and
nitrogen oxides.
Particulates contained in the flue gas are removed in a high efficiently fabric
filter or electrostatic precipitator. The flue gas is heated in a rotary heat
exchanger with flue gas from the SO2 converter. In the catalytic DENOX
reactor the nitrogen oxides in the flue gas are reduced selectively with
ammonia to free nitrogen. In the SO2 converter the sulphur dioxide is
oxidized catalytically to sulphur trioxide, which is recovered in the WSA
condenser as concentrated sulphuric acid. Ambient air preheated in the
WSA condenser is used as combustion air for the boiler.
The SNOx plant is fully automat zed and can be operated from the main
control room of a power plant without requiring additional manpower. There
is no hold-up of liquids or solids and response to variations in boiler load is
very fast. The process is adaptable to new or retrofit installations.
All equipment, apart from the WSA condenser, is made of carbon steel or
low alloy steel. The proprietary WSA condenser is in principle an air-cooled
multi-tube falling-film condenser with tubes of glass whereas other parts
in contact with the acid are lined with acid proof bricks or coated with acid
proof polymers. A SNOX plant has only few moving parts, resulting in low
maintenance costs and high on-stream availability.
95% of the sulphur contained in the flue gas is recovered as concentrated
sulphuric acid of commercial grade.
95% of the nitrogen oxides in the flue gas is reduced to free nitrogen.
Fly ash and trace metals in the flue gas are almost quantitatively
removed.
No waste products or wastewater is produced.
Apart from ammonia, no absorbents or auxiliary chemicals are used in the
process.
43
NOX ABATEMENT TECHNOLOGIES
The heat content of the flue gas is utilized down to 100 C and, together
with the heat of sulphuric acid formation, it is used for increased air preheat
and steam production.
The ammonia slip and most carbonaceous combustibles in the flue gas are
oxidized completely.
The volume of DENOX catalyst required for the denitrification of the flue
gas is substantially smaller than for an SCR process or an SCR process in
combination with other flue gas desulphurization processes.
The process is fully automated, the plant contains only few moving parts,
and there is no circulation of slurries or solids.
The operating costs decrease with increasing sulphur content in the flue gas.
Ref./Source: www.haldortopsoe.com
3.4 Conclusions
The design of the boiler, internal combustion engine, or gas turbine has a major
effect on the operation. NOx formation tends to increase with an increase in boiler capacity,
because larger boilers tend to have more intense combustion with higher combustion
temperatures and longer residence time for flue gases. The same appears to be true for
engines and turbines.
Different fuels require different combustion, abatement and control techniques.
For example different coals show a great variability in the content of volatile components.
The nitrogen content of fuel is important, as are the content of sulfur, lead, mercury and
other contaminants. Ultra-low nitrogen content fuels have been developed and are already
cost competitive. Thus, we can achieve some control of NOx from the lowered concentration
of nitrogen in the fuel without investing in changed burner design.
Tandem application (or use of hybrid control technology) of NOx control techniques
(first SNCR, then SCR in the duct, and then sorption before the ESP have been used to
achieve an overall reduction of 90+% in NOx and 80% in SOx.
Combustion of natural gas and petroleum distillates can be controlled in the
same way as pulverized coal. The major differences between coal and natural gas or oil
are that these better ones: (I) generally are lower in sulfur and ash; (II) usually are lower in
nitrogen; and (III) probably are lower in lead and mercury. Thus, gas and oil do not deactivate
a catalyst used in Selective Catalytic Reduction (SCR) at the same rate that coal or semi-
solid fuels do. The semi-solid petroleum products can actually have higher levels of sulfur,
nitrogen and other impurities than coal. They do not have as much char or ash as coal, but
have more than the lighter distillates.
Most of the NOx control systems are already available commercially available
notably name of the considered technologies have proved to basses performances and a
general applicably to all combustion system.
Please note that abatement and control of NOx from nitric acid manufacturing and
picklingbaths differs from abatement and control at combustion sources. Combustion
sources all have NOx in a large flow of flue gas, while nitric acid manufacturing plants and
pickling baths try to contain the NOx. Wet scrubbers (absorbers) can control NOx emissions
from acid plants and pickling, and can use either alkali in water, water alone, or hydrogen
peroxide as the liquid that captures the NOx. The wet scrubber operates by liquid flowing
downward by gravity through a packing medium, opposed by an upward flow of gas. Scrubbers
operate on the interchange of substances between gas and liquid. This requires that the
height of the absorber, type of packing, liquid flow, liquid properties, gas properties, and gas
flow should collectively cause a scrubber to have the desired control efficiency.
44
AIR POLLUTION CONTROL TECHNOLOGIES
3.5 References
1. Nitrogen Oxides: Impacts on Public Health and the Environment, EPA 452/R-97-002.
2. Selective Catalytic Reduction Control of NOx Emissions, SCR Committee of Institute of Clean Air Companies,
November 1997.
3. Nitrogen Oxides Control Technology Fact Book, Leslie L. Sloss, Noyes Data Corp., 1992.
4. NOx Control Technology Data, EPA 600/2-91-029.
5. Bauer F., Energy Engineering, 91 (1994) 17.
6. Alternate Control Techniques Document - NOx Emissions from Cement, Manufacturing EPA-453/R-94-004.
7. The Economic Feasibility of using Hydrogen Peroxide for the Ehanced Oxidation And Removal of Nitrogen
Oxides from Coal-Fired Power Plant Flue Gases, Hatwood J., Cooper C., AWMA Journal, March 1998.
8. Simultaneous SO2, SO3, and NOx Removal by Commercial Application of the EBA Process, Hirano S., Aoki S.,
Izutsu M, and Yuki Y., EPRI-DOE-EPA Combined Utility Air Pollution Control Symposium: The MEGA Symposium,
Atlanta, August 1999.
9. Update on SNAP Technology for Simultaneous SOx and NOx Removal, Felsvang K., Boscak V., Iversen
S., Anderson P., EPRI-DOE-EPA Combined Utility Air Pollution Control Symposium: The MEGA Symposium,
Atlanta, August 1999.
10. Iwamoto, M. and Hamada, H., Catal. Today, 10 (1991) 57.
11. Heck R.M. and Farrauto R.J., Catalytic air pollution control: commercial technologies, van Nostrand Reinhold,
New York, 1995.
12. Zwinkels, M., Jaras, S., Menon, P., and Griffin, T., Catal. Rev-Sci. Eng. 35(1993) 319.
13. Li, Y. and Armor, J.N., J.Catal., 150 (1994) 376.
14. Li, Y., Battavio, P.J. and Armor, J.N. (1993) J. Catal., 1993, 142, 561.
15. Alternative Control Techniques Document - NOx Emissions from Stationary Reciprocating Internal Combustion
Engines, EPA 453/R-93-032.
16. Alternative Control Techniques Document - NOx Emissions from Stationary Reciprocating Internal Combustion
Engines. EPA-453/R-93-032, July 1993.
17. Chess K., Yao S., Russell A. and Hsu H., Journal of the Air & Waste Management Association, 45 (1995)
627.
18. Anonimous, Oil & Gas Journal, 92 (1994) 134.
19. Manning M., Pipeline & Gas Journal, 222 (1995) 26.
20. Alternative Control Techniques Document - NOx Emissions from Stationary Reciprocating Internal Combustion
Engines. EPA-453/R-93-032, July 1993.
21. Bartok, W., and Sarofim, A.F., Fossil Fuel Combustion, John Wiley & Sons, New York, 1991
22. Kuehn S.E., Power Engineering, 98 (1994) 23-27.
23. Advanced Reburning for SIP Call NOx Control, EPRI-DOE-EPA Combined Utility Air Pollution Control Symposium:
The MEGA Symposium, Atlanta, August 1999.
24. States Report on Nitrogen Oxides Reduction Technology Options for Application by the Ozone Transport
Assessment Group, OTAG, 1996.
25. Alternative Control Techniques - Nitric Acid and Adipic Acid Manufacturing Plants EPA 450/3-91-026.
45
AIR POLLUTION CONTROL TECHNOLOGIES
Free radical reaction of SO2 with atomic oxygen in the high temperature zones.
Catalytic oxidation of SO2 on the surfaces of particles entrained in the gas stream.
Thermal reactions between SO2 and other inorganic gases generated during
combustion.
47
SOX ABATEMENT TECHNOLOGIES
Air pollution control systems for SO2 removal are large and sophisticated. Sulfur
dioxide is controlled by three different techniques: absorption, adsorption, and the use
of low-sulfur fuels. The control systems used for SO2 are usually not designed to remove
H2SO4. The sulfuric acid concentrations are usually below the levels where it is economically
feasible or environmentally necessary to install control systems. Table 4.1 shows the list
of desulfurization process and Table 4.2 shows the simplified desulfurization process for
developing countries.
1. Fuel modification
Coal preparation
Coal cleaning
Coal briquette including SOx absorbent
2. Fluidized bed combustion
Circulating fluidized bed combustion (CFBC)
Internally circulating fluidized bed boiler (ICFB)
*Advantages: Cost-effective for both initial and operating; easy to operate; 70-80% of SOx removal efficiency
48
AIR POLLUTION CONTROL TECHNOLOGIES
Mist
Eliminator
City Water
Recirculation Slurry
Fan
Flue
Gas
Absorber Alkali
Storage
Tank
Limestone Slurry
(Powder)
Pump
Lime or
Recirculation
Purge
Tank
Stream Feeder
Pump Clarifier
Slurry Pump
Mixing
Disposal
Solid to
Underflow
Vacuum Tank
Filter Pump
Pump
Figure 4.1: Scheme of a limestone wet scrubber system (adapted from ref 1)
49
SOX ABATEMENT TECHNOLOGIES
Spray towers scrubbers have the best design for sulfur dioxide removal. They
have a spray mechanism for introducing the slurry into the gas stream. Also, their simple,
open design presents fewer opportunities for the alkaline slurry to plug parts. The residence
time is also adequate for sulfur dioxide to be absorbed into the slurry droplets. Venturis
scrubbers are not a good choice in this situation because the residence time is too short. In
sulfur dioxide removal, there must be adequate contact between the pollutant gas and the
alkaline slurry for at least a minimal length of time. While Venturi scrubbers can be used to
remove both particulate and gaseous pollutants, they are primarily designed to maximize the
collection of particles by creating a large difference in velocity between particles and liquid
droplets in the gas stream. Venturi scrubbers also have large pressure drops, so they are
more expensive to operate than spray towers. Impingement plate scrubbers are not good
candidates in this situation because the alkaline slurry would plug the small holes in the
impingement plates.
The wet scrubber (absorber) vessels do not efficiently remove particulate matter
smaller than approximately 5 micrometers. However, as in the case with low-efficiency
particulate wet scrubbers, the particulate removal efficiency increases rapidly with particle
size above 5 micrometers. Usually, a moderate-to-high efficiency particulate control system is
used upstream from the sulfur dioxide absorber to reduce the particulate matter emissions
in the less than 3 micrometer size range. These upstream collectors also reduce the
quantity of particulate matter that is captured in the absorber. The evaporation of water that
occurs in wet scrubber vessels can keep gas temperatures relatively cold, in the range of
43 to 60 oC. These gas temperatures are well below the typical operating temperatures of
other air pollution control systems used on sources that generate sulfur dioxide emissions.
Another type of absorption system is called a spray atomizer dry scrubber, which belongs to
a group of scrubbers called spray-dryer-type dry scrubbers (Figure 4.2). In this case, alkaline
slurry is sprayed into the hot gas stream at a point upstream from the particulate control
device. As the slurry droplets are evaporating, sulfur dioxide absorbs into the droplet and
reacts with the dissolved and suspended alkaline material. Large spray dryer chambers are
used to ensure that all of the slurry droplets evaporate to dryness prior to going to a high
efficiency particulate control system. The term dry scrubber refers to the condition of the
dried particles approaching the particulate control system. Fabric filters or electrostatic
precipitators are often used for high efficiency particulate control. Spray-dryer-type absorption
systems have efficiencies that are similar to those for wet-scrubber-type absorption systems.
These generate a waste stream that is dry and, therefore, easier to handle than the sludge
generated in a wet scrubber. However, the equipment used to atomize the alkaline slurry
is complicated and can require considerably more maintenance than the wet scrubber
systems. Spray-dryer-type absorption systems operate at higher gas temperatures than wet
scrubbers do and are less effective for the removal of other pollutants in the gas stream
such as condensable particulate matter. The choice between a wet-scrubber absorption
system and a spray-dryer absorption system depends primarily on site-specific costs. The
options available for environmentally sound disposal of the waste products are also an
important consideration in selecting the type of system for a specific application. Both types
of systems are capable of providing high efficiency sulfur dioxide removal.
50
AIR POLLUTION CONTROL TECHNOLOGIES
Truck Delivery of
Calcium Oxide
Dilution
Water
Atomizer
Lime
Feed Tank
Silo
Slaking
Water
Slaker
Lime Slurry
Screen Fabric
Grit to Flue Filter
Disposal Gas
from
Boiler
Slurry Induced
Pump Spray Dryer Draft Fan
Calcium Hydroxide
Absorber
Slurry Holding Tank Air Pollution
Recycling System
Control System
(optional) Waste Product
Alkali
Storage
Tank
Note: flue gas recycle stream
and heat not shown
Feeder
Blower
Acid
Gas Particulate
Control Device
Induced
Combustion Heat
Draft Fan
Process Exchanger
Recycling System
(optional) Solid Residue
Figure 4.3: A flowchart for a dry-injection-type dry scrubber (adsorber) (adapted from ref 1)
51
SOX ABATEMENT TECHNOLOGIES
No. 2
Classification of technology: Air pollution control
Name of technology/technique: Activated carbon
Application: Reduction of exhaust SO2.
Description: Reduction of the amount of SO2 discharged, by installing the flue gas
desulfurization equipment in the factory, Nippon steel corporation
installed a dry type flue gas desulfurization equipment with activated
carbon. This system that does not require wastewater processing
and is suitable for processing large quantities of exhaust gas.
This process is based on adsorption/desorption reactions on activated carbon.
(I) Adsorption SO2 + H2O + O2 H2SO4
SO2 is adsorbed on the surface of the activated carbon and is oxidized to
form sulfuric acid.
52
AIR POLLUTION CONTROL TECHNOLOGIES
No. 3
Classification of technology: Air pollution control
Name of technology/technique: Magnesium hydroxide method wet type flue gas
desulfurization
Application: Coal burning boiler/Reduction of SOx in boiler exhausts gas.
Description: The compact and low-pressure loss magnesium hydroxide method with
high desulfurization and dust removal performance was introduced as the
flue gas desulfurization measures when installing the coal burning thermal
power station.
Mechanism of desulfurization reaction
1. Exhaust gas containing SO2 comes into contact with the absorption
fluid in the scrubber and, in addition to being humidified and cooled until
saturated, SO2 and dust are removed.
2. Air is blown into the bottom part of the scrubber, where magnesium sulfite
of low solubility is oxidized to the magnesium sulfate of high solubility.
SO2 + Mg(OH)2 MgSO3 MgSO4
3. Waste water from the desulfurization process is discharged after treatment
and sludge separation pH of fluid absorbed; 5.5 - 6.0, counter flow contact
spray type with extremely low-pressure loss suitable for removing dust with
grain diameter of 20~30 microns.
Advantages: 1. DeNOx: (Inlet) 240 - 260 ppm (Outlet) 20 ppm or below.
2. Dust removal: (Inlet) 30 - 40 mg/Nm3 (Outlet) 10 mg/Nm3 or below
Implementing company: Nippon Steel Corporation yard, Tokai Co-operative Power Company
Inc.
Ref./Sources: www.icett.or.jp
No. 4
Classification of technology: Air Pollution Control
Name of technology/technique: Scrubbers
Application: Paper/Pulp- Dust Removal and Desulfurization using Scrubbers
Description: Scrubbers are used with the objective of treating exhaust gas of a oil - fuel
boiler. The exhausted gasses have been previously treated in an electric
dust-precipitator. the gasses enter the main scrubber unit in a tangential
direction, rising as it creates a swirling motion. At the same time, liquid is
sprayed out radially from the spray nozzles in the center. The net effect is
that the swirling motion of the gas and the radial motion of the droplets
collect dust. The main reaction taking place in the absorption process:
2NaOH + SO2 Na2SO3 + H2O
The side reaction occurs:
Na2SO3 + SO2 + H2O 2 NaHSO3
53
SOX ABATEMENT TECHNOLOGIES
No. 5
Classification of technology: Air Pollution Control
Name of technology/technique: Absorption
Application: Food industry, Reduction of SO2 and Offensive Odors from Process Exhaust
Gas
Description: SO2 emissions could be reduced from 250ppm to below under 15ppm,
dust from 200ppm to below and the problem of bad smell was significantly
minimized. 60ppm. The reaction adopted for SO2 removal was:
SO2 + 2NaOH + NaOCl Na2SO4 + NaCl + H2O.
Deodorization, desulfurization and reduction of dust are carried out by
passing the exhausted gas through a sequence of a cooling tower, an alkali
washing tower and oxidizing tower.
Implementing company: Shikishima Starch Co., Ltd., Suzuka Factory
Ref/Source: www.icett.or.jp
No. 6
Classification of technology: Air Pollution Control
Name of technology/technique: Alkali scrubber (absorption tower)
Application: Chemical; Petrochemical industry/Reduction of SOx and dust in Process
Exhaust Gas
Description: The tecnology has been designed to neutralize SOx and capture dust and
steam vapor which are generated in the dissolving process of titanium ore
with sulfuric acid. The process use large amount of alkaline solution and
sea water for the following reactions:
SO3 + 2NaOH Na2SO4 + H2O
SO2 + 2NaOH Na2SO3 + H2O
Na2SO3 + 1/2 O2 Na2SO4
The amounts of discharged steam, SOx and dust were reduced by passing
the exhaust gas through a mist catcher, a cooler and an alkali scrubber. In
the scrubber, large amount of sea water are sprayed from the top of the
column counter-currently to the gas, and NaOH solution is sprayed from
nozzles located in several places at the middle of the column. Drain from
the scrubber is discharged after pH adjustment and passing through a
drain filter system.
Implementing company: Ishihara Sangyo Co., Ltd. Yokkaichi Factory
Ref./Source: www.icett.or.jp
No. 7
Classification of technology: Air Pollution Control
Name of technology/technique: Simplified limestone/lime gypsum process
Description: This is the simplified wet-type desulfurization system, realizing reduced
investment cost by simplifying the conventional limestone/lime gypsum
process. Kawasaki open spray tower is adopted for the absorber with high
performance spray nozzles and simple internal structures. Gypsum treatment
54
AIR POLLUTION CONTROL TECHNOLOGIES
No. 8
Classification of technology: Air Pollution Control
Name of technology/technique: Limestone-gypsum flue gas desulfurization system
Application: Boiler for the utility thermal power plant, boiler for industry-owned thermal
power plant.
This process has been adopted more than any other process in the world.
The reason is the facts. that limestone is a very cheap absorbent and
this process gives high desulfurization efficiency. Moreover, for the gypsum
as by-product has a commercial value since it can be used production of
plasterboard or as a retardant in the manufacture of cement.
Process Description: SO2 gas in the flue gas is absorbed by limestone and is oxidized by
reacting with the air accordingly to the following reaction.
CaCO3 + SO2 + (1/2) O2 + 2H2O CaSO4 2H2O + CO2
The by-product gypsum is recovered by centrifugation.
Advantages: (I) High efficiencies can be achieved.
Desulfurization efficiency: more than 96%
Dust removal efficiency: more than 90%
COD in wastewater: less than 10 mg/l.
(II) Limestone is less expensive than the other absorbents and gypsum has
a commercial value.
(III) It is necessary to provide the countermeasures against scaling and
build-up of solid in slurry liquid.
(IV) Spray tower is adopted as the Absorber, because its structure is simple
and has no scaling trouble.
Treated gas flow rate: 2,400,000 m3N/h
Inlet SOx concentration: 900 ppm
Desulfurization efficiency: 96%
Dust removal efficiency: 92%
COD in waste water: 5 mg/l
Ref./Source: Ishikawajima-Harima Heavy Industries Co., Ltd., www.ihi.co.jp.
55
SOX ABATEMENT TECHNOLOGIES
No. 9
Classification of technology: Air Pollution Control
Name of technology/technique: Mitsui-ge type flue gas SO2 removal system
Limestone or slaked lime is used as absorbent and gypsum is produced
as the by-product. Mitsui Mining delivered many systems for large-scale
thermal power plants with coal-fired boilers.
Description: In case of coal-fired thermal power plants, the fly ash and the acid gasses
can give undesirable effects on the quality of gypsum produced and can
reduce SO2 removal efficiency. Therefore, treatment method has to be
determined depending on the kind of coal used and the performance of EP.
(a) Soot mixing method. This method has been developed as the most
economical process to enable simultaneous dust and SO2 removal. Using
small amount of Na catalyst, Mitsui Minings achieved stable performance
of SO2 removal.
(b) Soot separating method
This method has been developed for various kinds of overseas coals- fired
thermal power plants. Pre-scrubber are installed in this configuration to
remove the impurities in flue gas. Stable performance of SO2 removal and
high quality of gypsum are achieved.
(c) Oxidizing methods
Oxidation inside of the absorber has been developed with patent of G.E.
(U.S.A.), and is able to recover high quality gypsum.
Performance: I) SO2 removal efficiency: More than 95%
II) Dust removal efficiency: Less than 15mg/m3N at outlet (in case of coal
fired (Thermal power plants)
III) Pressure loss: Less than 100 mmH2O as pressure loss of spray type
absorber
IV) By product: High quality gypsum.
Characteristics: I) This system uses the reliable spray type absorber with high performance.
In this absorber gas pressure loss is very low and the big capacity of gas
treatment with one tower is completely performed. Moreover, this system
has been improved for cutting cost and saving space, boost up fan for SO2
removal being excluded and served with IDF.
II) Against the fluctuations of gas volume, Mitsui Minings controlling system
can achieve the constantly stable performance.
III) The by-product of gypsum is of good quality, which can be used, as
material of plaster board and cement.
Ref./Source: MITSUI MINING CO., LTD
No. 10
Classification of technology: Air Pollution Control
Name of technology/technique: Hitachi wet limestone-gypsum FGD system
Description: Wet Limestone-Gypsum Flue Gas Desulphurization (FGD) System
removes SO2 (sulphur dioxide) contained in the flue gas in contact
with limestone slurry droplets as an absorbent when the flue gas
containing SO2 passes through the absorber. Limestone slurry absorbs
SO2 then it is oxidized by air at the lower part of absorber to produce
calcium sulphate which is extracted from the absorber as gypsum
slurry and finally dewatered and reused in the form of gypsum powder.
Chemical Reaction: CaCO3 + SO2 + 2H2O + (1/2)O2 CaSO4 . 2H2O + CO2
Advantages: I) SO2 removal efficiency higher than 90% can be achieved.
II) By-product gypsum can be reused as material of cement or wall board.
56
AIR POLLUTION CONTROL TECHNOLOGIES
No. 11
Classification of technology: Air Pollution Control
Name of technology/technique: Blue sky 2000 process
Description: This plant absorbs efficiently SO2 gas in the flue gas of oil or coal burning
boiler, glass melting furnace, kiln, etc. by calcium slurry with a little amount
of HCOOH. Moreover the dust in the flue gas is spontaneously removed.
The purity of gypsum as by-product is high and the gypsum can be sold for
cement and wall-board.
Advantages: 1. SO2 absorption efficiency: over than 95%
2. Dust conc. at absorber outlet: less than 0.03 g/m3N
3. Stoichiometric ratio of CaCO3: 1 - 3% excess
4. Gypsum purity: over than 90%
5. Pressure drop in absorber: less than 100 mmH2O
6. Purge liquid amount: less than 1/10 of conventional process
This process has the following characteristics by the addition of HCOOH.
1. High SO2 removal ratio even in a low pH range of 4.2 - 5.2
2. Preclusion of scaling and plugging
3. High stoichiometric utilization of the absorbent
4. Low liquid to gas ratio (L/G) and consequently lower energy consumption
for washing fluid circulation.
5. High SO2 absorption over the boiler load changes
6. Simple process, so small installation area
7. High Cl concentration in washing fluid, so little amount of purge liquor
Principle: The free HCOOH spontaneously dissolves the added calcium carbonate
intensively to form calcium formate, which is highly soluble in water. The
washing fluid then contains calcium formate in dissociated form and
provides a large amount of calcium ions for SO2 absorption from the flue
gas. Because of this, SO2 absorption ratio is enhanced very much. The
details of each section are as follows.
1. Absorption
The flue gas is contacted with the washing fluid in a cocurrent/countercurrent
two-stage absorber. SO2 is absorbed from the flue gas and reacts to form
bisulfite ions.
SO2 + H2O HSO3- + H+
Formate ions in solution react with the H+ formed during SO2 absorption.
H+ + HCOO- HCOOH
Thus, an intensive SO2 absorption occurs in the pH range 4.2 - 5.2, the pH
range that insures the formation of bisulfate, the only water-soluble form of
calcium and sulfur.
2. Oxidation
At the absorber pH of 4.2 - 5.2, oxidation occurs easily without the need for
an acidifying step. Dissolved oxygen in the washing fluid from boiler excess
air and injected air in the absorber sump react to form sulfate.
2HSO3- + O2 2H+ + 2SO42-
Calcium ions present in solution combine to produce gypsum.
Ca2+ + SO42- + 2H2O CaSO4. 2H2O
57
SOX ABATEMENT TECHNOLOGIES
3. Limestone addition
Limestone slurry is added to the absorber sump to replace the calcium
lost with the gypsum. At the low pH, limestone dissociates to produce a
washing fluid with dissolved calcium several orders of magnitude higher
than conventional process.
CaCO3 + H+ Ca2+ + OH- + CO2(g)
Ref./Source: TSUKISHIMA KIKAI CO., LTD.
No. 12
Classification of technology: Air Pollution Control
Name of technology/technique: The flue gas treatment system of the municipal solid waste
incineration plant
Application: This device is designed mainly for the treatment of exhaust gas generated
by the incineration of municipal solid waste. However, it can also be used
to process gases produced from various types of furnace.
Description: The exhaust gas generated from the incineration of municipal solid waste
contains harmful substances that cause air pollution, such as dust,
acid gases (SOx, HCl, NOx) and heavy metal particles (Pb, Zn, Cu, etc.).
This device removes wide range of these harmful substances with high
efficiency. The exhaust gas from the municipal solid waste incinerator is
cooled to a temperature of 180 to 200 C by the gas cooler, and then
enters the mixing chamber located at the inlet of the bag filter. Filtration
agency and hydrated lime transported by air from those silos are injected
into the mixing chamber. When mixed with the exhaust gas, the hydrated
lime reacts with hydrogen chloride and sulphur oxides, forming solid matter,
which is collected by the bag filter.
These chemical reactions are as follows:
2HCl + Ca(OH)2 CaCl2 + 2H2O
SOx + Ca(OH)2 CaSOx + H2O
The surface of the bag filter is also coated with filtration agency and hydrated
lime, and this coating effectively collects dust and heavy metal particles.
Advantages: 1. The device uses dry-type processing which does not affect the exhaust
gas temperature directly. Therefore, no corrosion or dust adhesion trouble
occurs in the equipment.
2. The filtering effect of the filtration agency and hydrated lime prevents
clogging of the filter cloth, providing stable plant operation without an
increase in the filtering pressure loss.
3. The filtering effect of the filtration agency and hydrated lime removes
dust and microscopic heavy metal particles effectively.
Processing capacity
1. Gas volume: no limitation
2. Gas temperature: 160 to 220 C
Ref./Source KURIMOTO, LTD.
No. 13
Classification of technology: Air Pollution Control
Name of technology/technique: Mitsui-bf dry type desox/denox process/mitsui mining
co., Ltd.
Description: Mitsui Mining successfully develops a dry-process, simultaneous
desulfurization and denitrification technology for commercial use on an
industrial scale. This process is applicable for SOx, NOx, dust and toxic trace
elements removal from boiler, furnace and chemical plant flue gases.
58
AIR POLLUTION CONTROL TECHNOLOGIES
59
SOX ABATEMENT TECHNOLOGIES
ACTIVATED COKE
Mitsui Mining produces high-quality activated coke maximizing the efficiency
of the Mitsui-BF process.
Advantages: Dry process
SOx removal efficiency higher than 98%, NOx removal efficiency higher than
80%
- Flexibility Simultaneous DeSOx/DeNOx, or DeSOx-only, DeNOx-only
operation
- Low power consumption - Minimum installation space required
- No waste water generated - Gas reheating not required - High quality by-
product
- Ease of operation - Low maintenance requirements
Ref./Source: Mitsui Mining co., Ltd
No. 14
Classification of technology: Air Pollution Control
Name of technology/technique: SOx reduction technology atmospheric fluidized bed
combustion boiler system (AFBC: Atmospheric Fluidized Bed Combustion)
Capacity: SOx removal efficiency more than 90%
Application: Coal-fired power station etc.
Description: When fluidization medium (limestone, sand etc.) placed on the distribution
panel (perforated panel) is supplied with air from beneath, the medium
floats in the air current within a specific range of the air speed, just as in a
state of boiling. The layer of floating medium in this state is referred to as a
fluidized bed. When coarsely crushed coal is continuously supplied into the
fluidization medium, which is heated in the air-heating furnace to the ignition
temperature of coal, the coal spontaneously starts burning. The furnace
is turned off at this point, and while the coal keeps burning, coal supply
volume is controlled so that the temperature of the fluidized bed stays at
760 to 860 C. For recovering heat, the fluidized bed combustion boiler has
heat exchanger tubes in its fluidized bed and convection section. The use
of limestone as fluidization medium enables in-furnace desulfurization. Flue
gas from the fluidized bed combustion boiler includes various unburned
components, which are collected by the mechanical precipitator and burned
in the after-burner furnace (CBC) to improve combustion efficiency.
Advantages: - In-furnace desulfurization/Fluidized bed combustion boiler can remove
SOx in the furnace while burning coal, using limestone as the fluidization
medium.
- Use of various types of coal/Since the fluidized bed combustion boiler
ensures stable combustion at low temperature, as compared to the
pulverized coal fired boiler, various types of coal can be used.
Ref./Source: The Kansai Electric Power Co., Inc.
4.6 References
1. Air Pollution Control Engineering, N. de Nevers, second Edition, 2000, Mc Graw Hill, New York.
2. Pollution: Causes, Effects and Control, R. M. Harrison Ed., The Royal Society of Chemistry, Cambridge,
1996.
60
AIR POLLUTION CONTROL TECHNOLOGIES
5.1 Introduction
In order to reduce the quantities of VOCs that are lost as fugitive emissions, it is
necessary to redesign the industrial processes, both form a chemical and an engineering
point of view. End-of-pipe technology (thermal incinerators, catalytic incinerators, liquid and
solids adsorbents, condensers, biodegradation.) must be applied when redesign of the
process is inapplicable or insufficient (1).
61
VOLATILE ORGANIC COMPOUNDS (VOCS)
350C
700-1000C
300C
Refractory-Lined
Combustion Chamber Heat Gas
Exchanger
Figure 5.1: Thermal oxidizer with recuperative heat exchanger (adapted from ref 1)
Thermal oxidizers have the broadest applicability of all the VOC control devices.
They can be used for almost any VOC compound. Thermal oxidizers can also be used for gas
streams having VOC concentrations at the very low concentration range of less than 10 ppm
up to the very high concentrations approaching 10,000 ppm.
Safety constraints impose to use thermal oxidizers for gas streams having VOC
concentrations not exceeding approximately 25% of the lower explosive limit (LEL). This
constrain has been introduced to be able to cope with possible short-term concentration
spike that would exceed the LEL. The 25% LEL limit depends on the actual gas constituents
and usually is in the 10,000 to 20,000 ppm range.
62
IR POLLUTION CONTROL TECHNOLOGIES
reversible reaction of a chemical with the catalyst and fouling is the coating of the catalyst
with a deposited material.) If the conditions are potentially severe, catalytic units are not
installed.
Clean Gas
Burner
(normally off)
Gas Inlet
Tubular Heat
Exchanger
Catalyst Bed
As with thermal oxidizers, catalytic oxidizers should not exceed 25% of the LEL, a
value that is often equivalent to a VOC concentration of 10,000 to 20,000 ppm.
The catalytic incineration method has become most popular because, in many
case, it is more versatile and economic for the low concentrations of organic emissions (i.e.,
<5,000 vppm).
The actual operating temperature and amount of preheat varies, depending on the
organic molecule, space velocity, composition of feed (i.e., contaminants water vapor, and so
forth), and organic concentration. Typical examples of operating temperatures are given in
Table 5.1. One-way of comparing thermal versus catalytic abatement is to look at the energy
required (air preheat temperature) to obtain quantitative removal of a given hydrocarbon. The
operating temperatures shown in Table 5.1 are well below the corresponding temperatures
necessary to initiate thermal (noncatalytic) oxidation. The catalyst initiates reaction at lower
temperatures. This demonstrates the major advantage of catalyzed processed, which is that
they proceed faster than noncatalytic reactions, allowing lower temperatures for the same
amount of conversion. This translates directly into improved economic for fuel use and less
expensive reactor construction materials, since corrosion is greatly reduced. Selection of
the catalytic material for various organic pollutants has been the subject of many studies.
Because metal oxides, precious metals, and combinations are used both for hydrocarbons
and chlorinated hydrocarbons. As a rule, precious metals (especially platinum and/or
palladium dispersed on carriers) are preferred because of their, resistance to deactivation,
and ability to be regenerated.
63
VOLATILE ORGANIC COMPOUNDS (VOCS)
Table 5.1: Operating temperatures for catalytic abatement of organic compounds (1)
5.2.3 Adsorption
Adsorption systems beds are generally used when the gas stream contains
one to three volatile organic compounds, and it is economical to recover and reuse these
compounds, or when a large number of organic compounds at low concentration, and it is
necessary to pre-concentrate these organics prior to thermal or catalytic oxidation.
Figure 5.3 shows the diagram of a multi-bed adsorber system used for collection
and recovery of organic solvent compounds. The VOC-laden gas is often cooled prior to
entry into the adsorption system to improve the effectiveness of adsorption. As the gas
stream passes through the bed, the organic compounds adsorb weakly onto the surfaces
of the adsorbent (high surface area activated carbon, zeolite, or organic polymer). When
the adsorbent is approaching saturation with organic vapor, a bed is isolated from the gas
stream and desorbed. Low-pressure steam or hot N2 is often used to remove the weakly
adsorbed organics. The concentrated stream from the desorption cycle is treated to recover
the organic compounds. After desorption, the adsorption bed is returned to service, and
another bed in the system is isolated and desorbed.
64
IR POLLUTION CONTROL TECHNOLOGIES
Steam
Bed 1
P VOC
To Atmosphere
Cooling Water
Particulate
Filter Bed 2
LEL
Solvent VOC
-laden
Air
A P T Bed 3
VOC
Purified
Fan Echaust Air
Solvent-laden
Exhaust Air Hot Air
(Desorption Air)
Pre-filter Rotary
Wheel Solvent-laden
Desorption Air
(Concentrated)
Adsorption systems are not recommended for gas streams that contain particulate
matter and/or high moisture concentrations because the particulate matter and moisture
compete with the gaseous pollutants for pore space on the adsorbent material.
The adsorption removal efficiency usually exceeds 95% and is often in the 98%
to 99% range for both solvent recovery and preconcentrator type systems. In both types of
units, the removal efficiency increases with reduced gas temperatures.
65
VOLATILE ORGANIC COMPOUNDS (VOCS)
VOCs can be removed by forcing them to absorb into an aqueous liquid or moist
media inoculated with microorganisms that consume the dissolved and/or adsorbed organic
compounds. The control systems usually consist of an irrigated packed bed that hosts the
microorganisms (biofilters). A presaturator is often placed ahead of the biological system to
increase the gas stream relative humidity to more than 95%. The gas stream temperatures
are maintained at less than approximately 40 C to avoid harming the organisms and to
prevent excessive moisture loss from the media.
Biological oxidation systems are used primarily for very low concentration VOC-
laden streams. The VOC inlet concentrations are often less than 500 ppm and sometimes
less than 100 ppm. The overall VOC destruction efficiencies are often above 95%.
Biological oxidation systems are used for a wide variety of organic compounds;
however, there are certain materials that are toxic to the organisms. In these cases, an
alternative type of VOC control system is needed.
66
IR POLLUTION CONTROL TECHNOLOGIES
Limiting the consideration of the VOCs control systems to gas streams having
total VOC concentrations less than approximately 25% of the LEL, it is possible to arbitrarily
divide the control system applicability into two separate groups: low VOC concentration (less
than 500 ppm) and high VOC concentration. It should be noted that there is no generally
accepted distinction between low and high concentration. The low concentration group can
be further divided into three main categories depending on the number of different VOC
compounds in the gas stream and the value of recovering these compounds for re-use
(Figure 5.5 ).
If there are a large number of separate VOC compounds, it is usually not
economically feasible to recover and reuse the captured organics. In this case, thermal or
catalytic oxidizers are used to oxidize the VOC compounds. Adsorbers can also be used as
independent control systems or as preconcentrators for the oxidizers.
If there are less than or equal to 3 VOC compounds, it is usually possible to use
either adsorbers or biological oxidation systems. However, it is necessary to confirm that
the compounds can be desorbed from regenerative-type adsorbers and that the specific
organics are not toxic to the microorganisms in biological oxidation systems. Both thermal
and catalytic oxidizers can also be used for these types of gas streams.
Figure 5.5: Scheme of general applicability of VOC control systems for low concentration sources
67
VOLATILE ORGANIC COMPOUNDS (VOCS)
Figure 5.6: Schema of general applicability of VOC control systems for high concentration sources
Allied Signal
ARI
Degussa
Engelhard Corporation
Haldoe-topsoe
Hereaas
Johnson- Mattey
Nikki Universal
Nippon shojubai
Prototech/united catalyst
W.R.Grace
The most reliable and acceptable means of destroying VOCs, HAPs, and odors
available today is thermal oxidation. Oxidation, typically, is an energy intensive technology
wherein a polluted air stream is heated to a high temperature setpoint that is predetermined
by the nature of the pollutant. The simplest form of an oxidizer is a direct-fired burner that
elevates the air temperature from incoming levels to combustion levels. Because of the high
cost of heating the process exhaust stream to the required oxidation temperature most thermal
oxidizers incorporate some type of primary heat recovery. Primary heat recovery transfers energy
from the hot clean gas stream exiting the oxidizer into the incoming polluted gas stream. This
reduces the amount of additional energy required to achieve the oxidation temperatures. There
are two widely used methods of recovering this thermal energy, recuperative and regenerative.
Sources: http://www.durrenvironmental.com
68
IR POLLUTION CONTROL TECHNOLOGIES
When a catalyst is used to enhance the operation of a thermal oxidizer, the system
is generally referred to as a catalytic oxidizer.
In many cases the most advantageous type of oxidizer can be selected based on
the following general guidelines. In other cases two or more oxidizer types may be practical
and a detailed economic analysis based upon the specific costs of fuel and electricity is
required to determine the best selection.
69
VOLATILE ORGANIC COMPOUNDS (VOCS)
if the airflow is large and has dilute concentration levels, unless additional secondary heat
recovery can be applied to the customers process.
70
IR POLLUTION CONTROL TECHNOLOGIES
Sources: http://www.durrenvironmental.com
71
VOLATILE ORGANIC COMPOUNDS (VOCS)
Advantages: Low running cost: Compared with the direct combustion system, this
equipment is capable of treating malodorous substance at low temperature.
Fuel costs can be reduced by 1/3.
Low boiling organic solvents and wider ranges of malodorous substances
can be purified.
72
IR POLLUTION CONTROL TECHNOLOGIES
VOCat RCO
This is a noble metal-based catalyst family, designed to either retrofit or build
up new regenerative oxidizers. It is useful to treat very large exhaust flows with a VOC
total amount of more than 1 g/Nm3. Those catalysts substantially lower operating costs of
regenerative oxidizers with a quick payback period (often less than 1 year).
The self-cleaning ceramic can degrade contaminants (e.g., oil) on the surface,
deodorize some harmful gases, and kill bacteria or virus. It can be used for indoor or outdoor
fitment for kitchen, toilet, natatorium, operating rooms, and so on.
73
VOLATILE ORGANIC COMPOUNDS (VOCS)
Source: http://www.nerc-cfc.com/production.html
5.6 References
1. Air Pollution Control Engineering, de Nevers N., second Edition, 2000, Mc Graw Hill, New York.
2. www.epin.ncsu.edu
3. Buscom.com
4. www.engelhard.com
74
AIR POLLUTION CONTROL TECHNOLOGIES
One of the first dioxin public awareness raising events may be considered the
accident at a chemical plant in Seveso, Italy on the 10th July 1976, when a toxic cloud
containing 2,3,7,8-tetrachloro-dibenzo-p-dioxin, the most toxic POP and one of the most
toxic man-made substances was released in the atmosphere. During the eighties the public
concern on POP emissions grew, focusing mainly on waste incinerators, which are the main
source of dioxins, but also on industrial organochlorine processes.
In the late eighties and in the nineties many local and international organizations
began considering the POPs problem with more attention. In May 1995, the UNEP Governing
Council adopted the Decision concerning Persistent Organic Pollutants. This process led in
2001 to the signature by the representatives of 92 countries of the Stockholm Convention
on POPs, which included a list of 12 substances. The Stockholm Convention is now signed
by over 150 countries and represents the main driving force in the international fight against
POPs. The detailed information on the state of the art on POPs and Stockholm convention
can be found on the websites of UNEP www.chem.unep.ch/pops and at www.pops.int.
75
POPS AND CHLORINATED ORGANIC POLLUTANTS
substances, once occurred in the gaseous emissions of industrial plants then can transfer
atmospherically over very long distances. Along with dioxins and furans also PCBs and HCB
can be formed as byproducts in some processes and are also designated by the Convention
as the so-called unintentionally produced (UP) POPs.
The provision is made in the Convention on POPs that all existing stockpiles of
intentionally produced industrial POPs (pesticides and PCBs) have to be destroyed and their
production be stopped. Regarding the UP POPs the Convention requires that their production
be minimized and eliminated where possible. With this aim two basic approaches can be
applied, namely prevention and end-of-pipe practices. This chapter will review some technical
aspects on these practices related in particular to the presence of POPs in air emissions.
It is known that many other chlorinated and halogenated substances also manifest
high or POP-like or toxicity. The 12 POPs by the Stockholm Convention are also comprised in
the list of 16 chemicals subject to the Geneva Convention on Long-Range Transboundary Air
Pollution (LRTAP). In addition to the 12 POPs, many other halogenated organic compounds
are on the list of persistent toxic substances (PTS), ozone depleting substances (ODS),
hazardous air pollutants, etc.
76
AIR POLLUTION CONTROL TECHNOLOGIES
its toxicity equivalent factor (TEF) was assigned one. The rule which defines the toxicity of a
dioxin / furan congener is exactly the presence of the four chlorine atoms at all of positions
2,3,7,8 of the structure. If at least one chlorine at these positions is missing the congener
is not toxic; if additional chlorines (up to eight possible) are present at other positions of
the rings, such congeners are normally less toxic (TEF less than 1). Therefore the measure
of dioxin contamination is usually presented in toxic equivalents (TEQ), i.e. the sum of
concentrations of all 17 congeners (they usually occur together) where for each conger its
component concentration is multiplied by its respective TEF. The TEQ value is often used in
regulatory limits, and for air contamination levels the PCDD/F usually range in the order of
nanograms per cubic meter TEQ.
Dioxins Furans
Figure 6.1. Toxic PCDD/PCDF congeners are shown which are characterized by the presence of chlorine atoms
at positions 2,3,7,8 (lateral) and chlorine or hydrogen atoms at positions 1,4,6,9 (in brackets)
Chlorinated dioxins and furans are the most toxic products of incomplete
combustion. The formation mechanisms for these compounds have not been yet completely
elucidated. It is believed that there are at least three possible types of formation mechanisms.
In principle, the dioxins are formed in any high temperature process given the presence of
organic matter, oxygen and chlorine. The first mechanism is the so-called pass-through
mechanism whereby the dioxins originally present in the combusted material are released
and exit unaltered. In the second mechanism, PCDD/F are formed from the precursors,
which are the chlorinated aromatic compounds possessing the appropriate structure to yield,
after structural rearrangement at elevated temperature, the structural skeleton of PCDD/F.
Typical precursors are chlorophenols and PCBs. Dioxins and furans can also be formed in
incinerators via the de-novo synthesis, which is a catalytic process that takes place on the
surface of fly ash in the presence of organic matter, oxygen, chlorine and a transition metal,
e.g. copper. PCDD/F formed by either of these mechanisms or their combination, normally
are adsorbed on the fly ash particles.
Usually the formation of dioxins from precursors occurs at cooling of the flue
gases. PCDD/F formation appears to be more favored over the temperature range from 240
to 540C. At temperatures well above 540C PCDD/F are readily oxidized. However, even
though high temperatures are involved in most incinerators, boilers and other combustion
devices and PCDD/F are initially destroyed, the chlorinated precursors, which originated in
the fuel and/or waste can volatilize and move with the gas stream through the combustion
process until they reach the temperature range favorable for dioxin and furan formation (240
to 540C).
There are several basic principles and approaches that should be applied to
reduce dioxin and furan emissions in combustion processes:
77
POPS AND CHLORINATED ORGANIC POLLUTANTS
Figure 6.2. Efficiency comparison of different post-treatment systems for PCDD/F removal in combustion plants.
78
AIR POLLUTION CONTROL TECHNOLOGIES
ods.html). There are many halogenated compounds on the EPA list of 188 hazardous air
pollutants (http://www.epa.gov/ttn/atw/188polls.html).
The standard techniques for elimination of VOC and particulate in flue gases
(see chapters 5 and 7) are usually suitable to get rid of the halogenated pollutants, as
well. However, in the case the chlorinated and halogenated VOC are chemically destroyed,
an additional problem connected with the formation of the halogen hydride arises. In some
cases this just can be solved by connecting a caustic scrubber right after the treatment
step. In other cases, this can result in harm produced to the system, e.g. catalyst poisoning,
corrosion, etc. In addition, some halogenated chemicals are more stable and resistant to
chemical treatment than normal VOC, which may require prolonged residence time of more
severe conditions. In some processes special treatment, e.g. special catalysts, may be
applied for chlorinated VOC removal which is different then for other VOC. On the contrary,
if the emission control systems are designed to remove dioxins and POP, as a rule, the
chlorinated VOC at the same concentrations can also be easily removed.
Should the chlorine containing materials be incinerated this must be carried out
in the proper manner, in strict conformance with the technical requirements defined by the
existing regulations. Since the dioxin formation is favored at cooling of the combustion
gases, containing incomplete combustion products and chlorine atoms, as was previously
mentioned, it is important to provide sufficient oxygen and temperature so that that, before
the effluents are cooled, the organic matter is exhaustively defragmented and oxidized
in order to suppress the pass-through and precursor routes of PCDD/F formation. The
standard rules require that the incinerators be designed so that the combustion gases
reside for at least 2 seconds in the zone of the furnace heated over 850C and in the
presence of at least 6% of oxygen.
79
POPS AND CHLORINATED ORGANIC POLLUTANTS
The particular attention should be paid to the best techniques and practices applied
to the incineration of the hazardous and other POP waste, e.g. PCB and stockpiled chlorinated
pesticides, since in this case the burnt material is the pure dioxin precursor and the risks of
dioxins emissions are particularly high as their formation is intrinsically inevitable. Although
this chapter is mainly dedicated to the techniques of reducing of UP POPs in emissions by
the end-of-pipe approach, which presumes that these dangerous compounds have been
formed, it has to be underlined that as in the case of MSW disposal practices, the alternative
techniques of hazardous chlorinated waste treatment should be given priority where possible.
A number of such modern techniques have been appearing recently and gaining popularity,
also thanks to the support of environmental and international organizations. These emerging
technologies are based on the processes other than incineration and high temperature
oxidative treatment (e.g. reduction based processes and low temperature oxidation), so that
the formation of PCDD/F is excluded by the nature of chemical process. UNIDO has been
promoting the introduction of non-combustion techniques through demonstration projects
with the support of GEF and of local governments in several countries. A number of such
newly emerged non-combustion technologies are in commercial operation in Japan, Australia,
Europe, Canada and USA and pilot and demonstration activities exist around the world. ICS-
UNIDO has recently published a review of non-combustion technologies for destruction of
stockpiled POPs (1).
80
AIR POLLUTION CONTROL TECHNOLOGIES
Figure 6.3. Organizational diagram of the rotary kiln type hazardous waste incineration plant. Reproduced from (2).
To widen the spectrum of approaches and methods that can be to destroy POPs
and chlorinated VOC in the gaseous phase it is useful also to consider here the post-
treatment systems employed in desorption processes, such as various technologies for
soil remediation or for treatment of other highly contaminated matrices (PCB equipment,
sludges, etc.) which are based on the evaporation of the contaminant as the first step. As
an example the soil remediation system based on vapor extraction could be considered, as
presented in Fig. 6.4. Unlike incinerators, where the end-of-pipe systems are designed to
treat micro amounts of pollutants (mainly PCDD/F), the post-treatment systems in desorption
technologies usually have to address high concentrations of pollutants in the air or vapor
steam (mainly original undestroyed contaminants which, in case if a chlorinated compound
is desorbed thermally, would also contain some amount of PCDD/F).
Treatment of gaseous effluents arising from the thermal desorption of polluted
soils as well as treatment of some gaseous streams from chemical industries containing
halogenated VOC is usually the same as applied for other VOC (post-combustion, catalytic
oxidation, adsorption, etc.) (3). However, in the case of treatment of halogenated VOC vapors
by oxidative techniques, post-treatment in caustic scrubber would be required in order to
remove hydrochloric acid. In addition, if catalytic oxidation is applied to treat halogenated VOC,
other catalyst formulations maybe used, especially for more resistant and more concentrated
pollutants, as the oxidation catalysts based on platinum or chromium or magnesium
oxides would be easily poisoned by acidic environment created by oxidation products.
Figure 6.4. Typical soil vapor extraction system. Reproduced from (4).
81
POPS AND CHLORINATED ORGANIC POLLUTANTS
The techniques and practices listed below in this and the following sections are
applicable not only for POP destruction but also for a majority of VOC and organic pollutants.
However, we have focused in a specific manner on the methodologies which are promising
for destruction of polychlorinated pollutants and which are not listed in chapter 5, including
some emerging ones. Before going to the techniques used to destroy POP and halogenated
pollutants in effluent gases (sections 6.6 and 6.7) lets consider some basic methods that
are used either i) to intensify the main combustion step (post- or secondary combustion, in
addition to the previously mentioned IR, UV, and MW intensification methods in incineration),
ii) to remove other hazards, e.g. chlorine and hydrochloric acid from combustion gases
(scrubbers; can be also considered as preventive to PCDD/F formation), or iii) to remove
contaminants physically without destruction (adsorption).
Scrubbers are essential in any process where chlorinated waste undergo thermal
high temperature treatment. Scrubbers remove hydrochloric acid or other halogen hydride
and free chlorine from the combustion gases by reaction with alkali solution. Concentrated
NaOH or KOH, CaOH solutions in water are usually used. This treatment is applied after the
gases exit from the furnace or the secondary combustion chamber. The alkaline solution is
introduced as a counter flow shower or the gases pass bubble through a vessel containing
the solution. Several scrubbers can be placed consecutively and can be followed with the
washing by pure water in a similar way. First scrubbers can be also designed in the way to
provide excellent heat exchange and rapid quenching of the combustion gases which helps
to order to reduce the dioxin formation rate. Scrubbing of incineration off-gases per se
cannot efficiently destroy halogenated chemicals; however, it eliminates hydrochloric acid
and chlorine gases formed during incineration, therefore also reducing the probability of new
POP formation in the post combustion zone.
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AIR POLLUTION CONTROL TECHNOLOGIES
coming from soil remediation by thermal desorption. Post-oxidation systems can be also
installed in other processes that yield gaseous emissions containing chlorinated organics
and POPs, such as organochlorine chemical production processes and non-combustion
hazardous waste destruction technologies.
Catalytic oxidizers and carbon filters are the essential components that allow
effective reduction of the dioxin levels in production sources to the acceptable/required
values. Unlike filters, the catalysts do not accumulate the pollutant and do not raise the
issue of their disposal. The activated carbon filters should be more frequently replaced
than catalysts. This increases the cost of operating incinerators, however even very stable
catalysts require periodical replacement as these can be poisoned/deactivated by a number
of substances that present in the emissions. Because of this, the catalysts may contribute
more than the other post-treatment process modules to the overall maintenance and
consumables costs of the plant. Many new catalysts and processes capable of treating
streams containing chlorinated hydrocarbons have been commercialized in the last years.
Figure 6.5. Basic arrangement of the catalytic oxidation module. Reproduced from (5).
83
POPS AND CHLORINATED ORGANIC POLLUTANTS
Figure 6.6. Remedia Dioxin/Furan Catalytic Filter System. Reproduced from www.gore.com/remedia.
Photolytic (UV) oxidation technologies use UV light to ionize the organic molecules,
by breaking molecular bonds and creating free radicals. UV or near UV light can be used
(150-350 nm) which is sufficient to destroy VOC and chlorinated VOC. The free radicals
formed from oxygen and pollutant molecules then recombine and yield harmless oxidation
products, such as carbon dioxide, water, and hydrogen chloride, in the case of chlorinated
pollutants. Similar photo-catalytic technologies use UV light in the presence of titanium
dioxide (TiO2) as a catalyst. The catalytic UV oxidation techniques allow carrying out the
reactions at moderate or ambient temperatures.
Figure 6.7. Flow diagram of the PTI photolytic destruction process. Reproduced from US-EPA (8).
84
AIR POLLUTION CONTROL TECHNOLOGIES
Figure 6.8. Basic arrangement of the biofiltration process. Reproduced from (5).
85
POPS AND CHLORINATED ORGANIC POLLUTANTS
Figure 6.9. Basic scheme of the non-thermal plasma set-up for treatment of pollutants in gaseous emissions.
Reproduced from (4).
The principle components of a typical non-thermal plasma system (Fig. 6.9) are
the reactor vessel and, if chlorinated compounds are treated, an acid scrubber. The reactor
cell is connected to the power supply and control system for corona production. In a gas-
phase corona reactor, contaminated influent gas is forced through a reaction chamber, where
it is ionized by plasma. The reaction produces carbon dioxide and water, and in the case of
halogenated hydrocarbons, halogen hydride.
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AIR POLLUTION CONTROL TECHNOLOGIES
There are not too many non-combustion chemical technologies that have been
specifically designed to treat concentrated chlorinated chemicals in effluents. The three
non-combustion POP destruction processes that can treat gaseous streams directly are
Gas-Phase Chemical Reduction (GPCR) and PLASCON, an in flight plasma arc system.
Plasma arc processes are sometimes assimilated to incinerators, but there are several
substantial differences that concern the nature of processes, design, and efficiency. As for
the two above, CerOx process can also be considered theoretically applicable to gaseous
emissions. In practice, none of these processes have been applied as an additional air
pollution control module as these were designed for macro concentrated waste disposal.
Some other processes, such as MCD (Mechanochemical Decomposition) by EDL in Australia
and BCD (Base Catalysed Decomposition) by BCD Int. can also treat vaporised pollutants
coming after desorption processes, however the treatment in these processes takes place
in the dense phase, i.e. after condensation of the pollutants, therefore, such technologies
can not be considered directly applicable to gaseous effluents.
The process (see Fig. 6.10) can treat basically all types of chlorinated waste in
different forms, namely bulk organic solids and liquids, high-strength PCB oils and mixed
solid materials, aqueous waste, contaminated soils and sediments.
Since the GPCR process is based on the gas-phase reaction it is provided with a
gas fed module, so POPs and other chlorinated organics present in the gaseous state can
be treated directly in the continuous manner. This makes this technology a possible option
to couple to a facility which produces POP emissions. However, the costs of this technology
setup and operation may be considered too elevated to be applied for destruction of micro
amounts of pollutants in the gaseous phase. This technology shows excellent destruction
efficiencies but can be suitable only for the oxygen free gaseous streams containing high
concentration of chlorinated pollutants.
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POPS AND CHLORINATED ORGANIC POLLUTANTS
Figure 6.10. Organizational diagram of the GPCR process. Reproduced from (9).
PLASCON, now marketed by DoloMatrix Int. Ltd., is an argon plasma arc process
and is designed to process CFC and organic liquids, such as PCBs. PLASCON is an in flight
plasma process which operates in the gaseous phase in the continuous regime (Fig. 6.11).
The waste mixes directly with the argon plasma column. Argon is used as the plasma gas
since it is inert and does not react with the torch components. The waste is fed directly into
the plasma torch within the current of argon, where it is rapidly heated (one millisecond) up
to 12.000C and then passes into the flight tube where its pyrolysis occurs in nearly 20 ms
at temperature of about 3000C.
Figure 6.11. Basic scheme of the PLASCON plasma torch system. Reproduced from the vendor website (www.
srlplasma.com.au) and (10).
88
AIR POLLUTION CONTROL TECHNOLOGIES
In the beginning of the flight tube oxygen is also added (limited amount) to ensure
that any carbon formed during pyrolysis is then converted to carbon monoxide. The high
temperature generated by plasma causes compounds to dissociate into their elemental ions
and atoms. Recombination occurs in a cooler area of the reaction chamber, followed by rapid
(2 ms) alkaline quenching from 1500C to less than 100C. Such rapid quenching prevents
the formation of dioxins and furans. The PLASCON process is applicable to the gaseous
streams and was successfully applied for destruction of CFC in Australia. In principle, it can
be applied as an add-on module to the processes that yield gaseous emissions containing
high concentrations of POPs and chlorinated VOC. The process is highly efficient, easy in
operation and compact, however maybe costly for low concentrated pollutants due to high
electricity and argon consumption.
The organic molecule to be destroyed is being put in contact with the aqueous
solution of Ce4+ species, which is a strong oxidizing agent. Ce4+ then vigorously reacts with
the organics oxidizing it to CO2 and water and being itself reduced to Ce3+. After the cerium
anion is reduced to Ce 3+ by taking an electron from an organic compound, it is brought to
the electrochemical cell where it is reoxidized back to Ce4+. The latter is again introduced in
the reaction vessel thereby closing the process cycle. The two consecutive process modules
treat organics in water and in the gas phase respectively (see Fig. 6.12). The second reactor
module is designed to treat VOC and partial oxidation products in the emissions arising from
the first step. It uses a counter current flow of Ce4+ allowing the Ce4+ to oxidize organics.
Figure 6.12. Gas-phase CerOx treatment. Reproduced from the vendor website (www.cerox.com).
89
POPS AND CHLORINATED ORGANIC POLLUTANTS
The gas phase reactor can process small amounts of VOCs and can be sized to
handle large quantities of compounds that transform into gas phase at lower than 95C. In
this connection, its application to treat chlorinated chemicals in emissions can be considered
a possible option.
6.9 References
1. S. Zinoviev, P. Fornasiero, A. Lodolo, S. Miertus, Non-combustion technologies for POP destruction. Review
and Evaluation, ICS-UNIDO Publications, 2007 (in press).
2. H.-U. Hartenstein, Performance of commonly used combustion technologies for POPs destruction, in STAP/
GEF Technical Workshop on Emerging Innovative Technologies for the Destruction and Decontamination of
Obsolete POPs, Washington, 1-3 October 2003.
3. Off Gas Treatment Technologies for Soil Vapor Extraction Systems: State of the Practice, U.S. EPA, March
2006, EPA-542-R-05-028.
4. Guide for Conducting Treatability Studies Under CERCLA, Soil Vapor Extraction, U.S. EPA, September 1991,
EPA/540/2-91/019A.
5. FRTR Remediation Technologies Screening Matrix, available at www.frtr.gov.
6. M. Plinke, R.L. Sassa, W.P. Mortimer Jr., G.A. Brinckman, US 5620669, 1997.
7. Alternative technologies for the Destruction of Chemical agents and Munitions. National Research Council,
Washington D.C.: National Academy of Sciences, 1993.
8. Technology Profiles Eleventh Edition. Volumes 1-3, U.S. EPA, September 2003, EPA 540/R-03/501.
9. GPCR presentation at South American regional workshop on the environmentally sound destruction of POPs
and the decontamination of POP containing waste in the framework of Basel and Stockholm conventions,
San Pablo, Brazil, 7-10 December 2004, available at crsbasilea.inti.gov.ar/evento11.htm.
10. T. Bridle, Scheduled Waste Management: The Australian Experience, in POPs Workshop on Emerging
Innovative Technologies for the Destruction and Decontamination of Obsolete POPs, 1st-3rd October 2003.
90
AIR POLLUTION CONTROL TECHNOLOGIES
Definitions
Particulate matter (PM) is a major class of air pollution. Black smoke, or soot,
is the most visible emission, but other, less visible pollutants are emitted. Combustion
and non-combustion industrial processes, mining and construction activities, vehicles and
incinerators are examples of potential sources of particulate. Beside these antropogenic
emissions, natural sources (volcanos, forest fires, wind storm, and so forth) are present,
enhancing the negative impact on a global scale. An enormous number of parameters influence
the particulate formation/ageing process, which leads to particulate matter in large variety
of shapes and sizes, and therefore of physical and chemical properties. The concept of
aerodynamic diameter has been developed to describe, in a simple and universal way, how
a particle behaves in air. The aerodynamic diameter is the diameter of a spherical particle
having a density of 1 gm/cm3 that has the same inertial properties (i.e. terminal settling
velocity) in the gas as the particle of interest. The range of particle sizes of concern for air
emission evaluation is quite broad. The Environmental Protection Agency (EPA) (http://www.
epa.gov) has defined four terms for categorizing particles of different sizes (Table 7.1).
Using this division of particulates according to their size, the EPA has identified
various categories of particulate emission for the purposes of defining emission control: (I)
Total Suspended Particulate Matter (TSPM); (II) PM10; (III) PM2.5; (IV) particles less than 1
micrometer; and (V) condensable particulate matter. As outlined below, these categories are
based on the environmental impact of each.
Total Suspended Particulate Matter includes a broad range of particle sizes from
0.1 m to about 30 m in diameter, ie, fine, coarse, and supercoarse particles.
PM10 is defined as particulate matter with a diameter of 10 m collected with
50% efficiency by a PM10 sampling collection device. However, for convenience, the term
PM10 is often used to include all particles having an aerodynamic diameter of less than or
equal to 10 m. PM10 is regulated as a specific type of "pollutant" because particles in this
size range can penetrate into the lower respiratory tract.
91
TECHNOLOGIES FOR PARTICULATE EMISSION CONTROL
Housing
Grinding
Whell To Fan
Parent
Material
Particles
and Air
Air Handling
Hood Duct
Figure 7.1: Particulate generated by physical attrition during the operation of a grinding wheel (adapted from ref 1)
92
AIR POLLUTION CONTROL TECHNOLOGIES
Formation of PAH
CH4 aromatic rings (Polycycle Aromatic
Hydrocarbons)
Methane fuel
Desorption
Pyrolise Chemical
condensation
Pyrens
Reactive small
molecules and radicals
Graphitisation
CH3 H C C H
Methylradical Acetylene
Corones
Desorption
C3H3 C6H5
Propargylradical Phenylradical
Ovalenes
Figure 7.2: Simplified schema of particulate formation hypothesis of radicals during methane combustion
During heating of the particles in the flame, their chainlike, aliphatic structure
is increasingly converted into aromatic rings and compounds, as a consequence of the
extraordinary aromatic stability. Subsequently, the polyaromatic compounds may detach
from the particles when they lay at the surface and all chemical bonds are saturated. As
heating continues the particles form increasingly larger arrays of aromatic rings, becoming
more and more graphitic and therefore denser. The particles tend to coagulate and pick up
small radicals and acetylene for surface growth.
93
TECHNOLOGIES FOR PARTICULATE EMISSION CONTROL
Figure 7.3: Municipal waste incinerator: homogeneous and heterogeneous nucleation of particulate (adapted
from ref 1)
Droplet evaporation is caused by air pollution control systems that use recycled
water from wet scrubbers (vide infra) to cool the gas streams. The recycled water, containing
solid materials, is injected into the hot gas streams. The evaporation of the small water
droplets leads to release of the suspended and dissolved solids as small particles in the
size range 0.1 to 20 m.
A gravity settler (Figure 7.4) is a long chamber through which the polluted gas is
forced to pass slowly, allowing time for particles to settle by gravity to the bottom. These
devices are used only for large particles (diameter greater than 75 m). In fact, the very low
terminal settling velocities of most particles encountered in the field of air pollution limit the
usefulness of gravity settling chambers. The cross section area (WH) is much larger than
that of the duct approaching it, so that the linear gas velocity inside the chamber is lower
94
AIR POLLUTION CONTROL TECHNOLOGIES
that in the inlet duct, thereby favoring settling of particulate. These devices must be cleaned
manually at regular intervals, but their design and construction are simple. Through the last
three decades, the stringent control requirements adopted have resulted in a sharp decline
in the use of this type of collector. However, these devices still have some use in treating
very dirty gases from metallurgical industries.
Gas Flow
OUT
W
H Outlet Baffles
L
Gas Flow
IN
Inlet Baffles
Inlet
Cyclone body
Dirty Gas
Conical Section
Dust
95
TECHNOLOGIES FOR PARTICULATE EMISSION CONTROL
Traeted Gas
Outlet Tube
Dirty Gas
Inlet
Spinner
Vane
Collecting
Tube
Fly Ash
Particle
The term scrubber was originally used to describe a device for collecting fine
particles on liquid drops. Nowadays, this term has a more general meaning. In fact, even
devices using a liquid to control sulfur dioxide emission, are called scrubbers.
The basic idea of scrubber is to make a liquid drop and the particle touch each
other, so that the particle will adhere to the drop. Therefore it is necessary to properly
introduce a large number of liquid drops (normally water) into the gas stream. The mixture
of the gas and liquid containing the particulate can easily separated in a cheap cyclone, as
depicted in Figure 7.7. Finally, the liquid can be separated from the solid, and recycled.
96
AIR POLLUTION CONTROL TECHNOLOGIES
Scrubber Cyclone
Dirty gas Mixed gas Clean gas
gas-liquid gas-liquid
and liquid
contactor separator
Dirty liquid
Contact of the water drops with the gas to be cleaned may be achieved in a number
of ways. In cross-flow scrubbers (Figure 7.8), multiple spray nozzles are located on the roof
of the scrubber and dispense uniformly the liquid over the horizontally incoming gas. The
liquid is collected at the bottom of the device. Efficiency improves with decreasing drop size
and increasing height of the scrubber. However care must be taken to ensure that the drops
size is not too small, as this may result in a too slow vertical velocity. If this is slower than
the horizontal gas velocity, the drops can pass out with the gas and they will therefore not
be collected in the scrubber. This may represent a serious limitation for certain applications.
Liquid in
Liquid out
Figure 7.8: Scheme of a cross-flow scrubber (adapted from ref 1)
In counter-flow scrubbers (Figure 7.9) the spray nozzles, are located in the roof
of the scrubber. The liquid falls by gravity. The gas stream enter from the bottom of the
scrubber and flows upwards. In this configuration a potential drawback is blowing the drops
out through top of the scrubber (ie, in the wrong direction).
97
TECHNOLOGIES FOR PARTICULATE EMISSION CONTROL
In co-flow scrubbers (Figure 7.10), both the gas and the liquid enter at the left
and exit at right. However, the liquid enters at right angle to the gas flow. The gas velocity is
partially reduced by the liquid injection.
Liquid out
Liquid in
All three of these general methods have been incorporated into the many types
particulate wet scrubbers are used in industrial processes: Venturis, impingement and sieve
plates, spray towers, mechanically aided, condensation growth, packed beds, ejector, mobile
bed, caternary grid, froth tower, oriented fiber pad, wetted mist eliminators. As this list is
quite extensive, for brevity only selected samples will be discussed here.
A typical co-flow Venturi scrubber is shown in Figure 7.11 (9). Particulate matter,
which accelerates as it enters the throat, is driven into the slow moving, large water
droplets that are introduced near the high velocity point at the inlet of the Venturi throat.
The adjustable dampers in the unit illustrated are used to adjust the open cross-sectional
area and thereby affect the speed of the particles entrained in the inlet gas stream. Venturi
scrubbers include the following different design types: (i) fixed throat, (ii) adjustable throat,
(iii) collision (opposed-adjustable), (iv) single rod decks, and (v) multiple rod decks.
Gas Inlet
Spray
Header
Liquid
Inlet Throat
Movable
Throat
Dumper
Gas Outlet
Outlet
Figure 7.12 shows an impingement plate scrubber. These scrubbers usually have
one to three horizontal plates, each of which has a large number of small holes. The gas
stream accelerating through the holes vapourises water droplets in the water layer above the
plate. Particles impact with these water droplets.
98
AIR POLLUTION CONTROL TECHNOLOGIES
Clean Gas
Mist Eliminator
Liquid Inlet
Plate
Downcomer
Dirty Gas
Figure 7.13 report a typical spray tower scrubber. This is the simplest type of
particulate wet scrubber in commercial service. Sets of spray nozzles located near the top
of the scrubber vessel generate water droplets that impact with particles in the gas stream
as the gas stream moves upwards.
Clean Gas
Liquid Sprays
Dirty Gas
99
TECHNOLOGIES FOR PARTICULATE EMISSION CONTROL
The negatively charged dry precipitators are the type most frequently used on
large applications such as coal-fired boilers, cement kilns, and kraft pulp mills. They are also
widely used in air conditioning systems for buildings . In this case, charging and collecting
are carried out in separate parts of the electrostatic precipitator, giving the name of two
stage precipitators. Wetted-wall precipitators (sometimes called wet precipitators) are often
used to collect mist and/or solid material that is moderately sticky. The positively charged
two-stage precipitators are used only for the removal of mists.
Electrostatic precipitators can have very high efficiencies due to the strong
electrical forces applied to the small particles. These types of collectors can be used when
the gas stream is not explosive and does not contain entrained droplets or other sticky
material.
Corona Discharge
along the Length Clean Gas
of a Wire
Dirty Gas h
Lower
Wire
Collected Dust
Support
on Plates
Figure 7.14: Scheme of an electrostatic precipitator with two plates and four wires (adapted from ref 1)
7.3.5 Filters
Filters divide the gas flow into smaller parts where they can collect the particles.
In general two categories of filter are used in air pollution control: surface filters and depth
filters. Construction of filters with holes as small as many of the particle to collect is very
difficult. Therefore, in general, the sizes of the holes of industrial filters are significantly
bigger than the particle diameter. Nevertheless, they act as efficient surface filters (Figure
7.15a), as, when fine particles are caught on the side of a hole, they tend to bridge over the
hole, reducing its dimensions. The cake of collected material becomes the effective filter,
while the original filter act as a support. The growing cake have average pore size smaller
than the diameter of the incoming particles. The particulate is collected on the front surface
of the cake. For that reason this is called a surface filter.
Depth filters (Figure 7.15b) are the other important class of filter used in air
pollution control. They collect particles throughout the entire filter body. Each layer has
the same filtration efficiency, however mass deposition decrease logarithmically from inflow
to outflow. The separation efficiency depends on pore size of the filter (or the particulate
diameter), on the depth of the filter, and on the gas velocity (13-14).
100
AIR POLLUTION CONTROL TECHNOLOGIES
Figure 7.15 a: Wall flow filter, surface filtration Figure 7.15 b: Depth filter, depth filtration
(adapted from ref 1) (adapted from ref 1)
No. 2
Classification of technology: Air Pollution Control
Type of Industry: Petroleum refining
Subject: Reduction of Dust Discharged from Catalyst Regenerator
Purpose: To reduce the dust in the exhaust gas discharged from the catalyst
regenerator unit of the fluidized catalytic cracker from 0.30 g/Nm3 to 0.03
g/Nm3.
Details: Normally, the dust concentration is high in the exhaust gas discharged from
the catalyst regenerator unit, since it contains scattered catalysts. The
electric precipitator was therefore installed to collect the dust and to clean
the exhaust gas.
Principle: The basic structure of the electric precipitator consists of 1) electric
discharging poles, 2) dust collecting poles to collect the dust charged by
corona current, ) striking devices to release the dust adhering to the pole
101
TECHNOLOGIES FOR PARTICULATE EMISSION CONTROL
7.5 References
1. Air Pollution Control Engineering, N. de Nevers, second Edition, 2000, Mc Graw Hill, New York.
2. Pollution: Causes, Effects and Control, R. M. Harrison Ed., The Royal Society of Chemistry, Cambridge,
1996.
3. Gruenberger TM, Moghiman M, Bowen PJ, Syred N, Combustion Science and Technology, 2002, 174 (5-6):
67-86.
4. Barone AC, DAlessio A, DAnna A, Combustion and Flame, 2003, 132 (1-2): 181-187.
5. Cooke MJ, Ford NJ, Pragnell RJ, Journal of the Institute of Energy, 1991, 64 (461): 239-246.
6. Easom BH, Burlatsky SF, Altman RF, Chang R, Pollution Engineering, 1999, (7): 40-42.
7. Jaworek A, Balachandran W, Krupa A, Kulon J, Lackowski M, Environmental Science and Technology,40 (20):
6197-6207 OCT 15 2006
8. Lehner M, Hoffmann A, Chemical Engineering & Technology, 2004, 27 (7): 722-728.
9. Ananthanarayanan NV, Viswanathan S, Industrial & Engineering Chemistry Research, 1999, 38 (12): 4889-
4900
10. Kim SH, Lee KW, Journal of Electrostatics, 1999, 48 (1): 3-25.
11. Zukeran A, Looy PC, Chakrabarti A, Berezin AA, Jayaram S, Cross JD, Ito T, Chang JS, IEEE Transactions on
Industry Apllications, 1999, 35 (5): 1184-1191.
12. Prasad NVPRD, Lakshminarayana T, Narasimham JRK, Verman TM, Raju CSRK, IEEE Transactions on Industry
Apllications, 1999, 35 (3): 561-567
13. Jung SC, Park JS, Yoon WS, Iternational Journal of Automotive Technology 8 (2): 165-177 APR 2007
14. Yamamoto K, Ochi F, Journal of the Energy Institute, 2006, 79 (4): 195-199
ReRere
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AIR POLLUTION CONTROL TECHNOLOGIES
Combustion turbines that burn fuel to generate heat are widely used for the co-
generation of electricity and steam.(1) Gas turbines have usually a coaxial centrifugal air
compressor. The preheated and compressed air at 200 - 500 C meets the fuel stream
in the combustion chamber. The exhausted gas have a temperature up to 1600-2000 C,
which is too high for the turbine. Therefore, part of the air is by-passed to cool the combus-
tion gas before it goes to the turbine. Notably that nitrogen oxides are formed during the
combustion process, trough the various mechanisms previously discussed in Chapter 3. We
need to recall that the formation of thermal-NOx is significant at temperatures above approxi-
mately 1500 C while prompt NOx is only significant at close to stoichiometric conditions in
flame combustors. Finally, the NOx formed as a reaction intermediate, is significant at low
temperatures in and is unstable at higher temperatures. The combustion of fuel containing N
bound species most likely involves the thermal decomposition of the bound nitrogen species
upstream of the combustion zone. Therefore, significant amounts of low molecular weight
molecules, such as NH3, NH2, NH, HCN, CN., can be fed to the gas turbine and partially
remain in the exhaust.
The existing methods for NOx control in gas turbines includes prevention strategies
to control the combustion and endoff pipe measures to clean up the exhaust gas. Primary
measures include, beside catalytic combustion, water or steam injection, lean-premixed
combustion and staged combustion. In this respect it mast be notice that since the 1980s,
a common practice in operation of these gas turbines has been to use water or steam
injection to lower the combustion flame temperature to reduce the NOx emissions. However,
the quenching of the flame results in increased CO and hydrocarbon (HC) emissions. In fact,
the use of water or steam injection typically can reduce the NOx emissions from 150 vppm to
about 40 vppm, with a concurrent increase in CO emissions from 10 vppm to as high as 400
vppm and an increase in hydrocarbon emissions. Furthermore, a water purification stage is
need and water injection can lead to corrosion problem and / or can alter the combustion.
However, water injection is still a viable technology, and in some case is used in combination
with new burner developments and end-off pipe technology.
Lean-premixed combustion has been introduced lately and gives low emission
levels, typically around 25 ppm thermal-NOx. The drawback of this approach is that a
complicated and expensive control systems must added.
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ABATEMENT OF THE HYDROCARBON AND CO EMISSIONS FROM GAS TURBINE
Fig. 8.1 Schematic representation of a catalytic combustor and a flame combustor in an open-cycle gas turbine.
104
AIR POLLUTION CONTROL TECHNOLOGIES
can be used to heat the gas to the catalyst ignition temperature. However, this requires a
careful designed, to control the amounts of thermal-NOx (4).
The main factors which influence the maximum outlet temperature of the combustor
are the amount of cooling air, homogeneity or pattern factor of the fuel-air mixture temperature
losses in the transition duct between combustor and turbine, turbine inlet temperatures and
adiabatic temperature rise on combustion of the fuel. Finally, it must be noted that gas
turbines are designed for a specific turbine inlet temperature, which is not the same as
the combustor outlet temperature. For example, if the gas turbine is designed for an inlet
temperature of 1250 C, approximately 100 C could be lost in cooling air and temperature
losses in the transition duct. Further, a 5% inhomogeneity in the air-to-fuel mixing could give
a temperature deviation of 50C in adiabatic temperature rise. Therefore, the catalyst
must be designed to work at 1400 C and not at 1250 C.
Combustor can be made without any large change in the gas turbine design.
While NOx emissions from gas turbine have been the subject of many regulations,
only recently abatement of HC, CO and SOx have been considered. Notably that air quality
regulations have for long time not even considered methane emissions. This is because
methane is non toxic and is largely considered unreactive with regards to the atmospheric
processes that cause photochemical air pollution. Thus, hydrocarbon reduction efficiency
usually concerns the destruction of nonmethane hydrocarbons (NMHC). To meet these
requirements, new catalysts has been developed for simultaneous CO and HC removal
(5-7).The catalytic oxidation activity of these catalysts, strongly depends on the type of
hydrocarbon. For example, unsaturated or substituted hydrocarbons such as alkenes (e.g.,
propylene), aromatics (e.g., toluene), and aldehydes (e.g., formaldehyde) are much easier
to oxidize (i.e., require lower temperature) than saturated paraffins such as propane. Among
saturated compounds, those with lower carbon numbers are more difficult to convert than
those with higher carbons numbers (e.g., propane is much more difficult to convert than
hexane).
Hydrocarbons in the exhaust of combustion turbines are composed of combustion-
derived and fuel-derived products. Fuel-derived hydrocarbons are uncombusted
hydrocarbons from the fuel that reached the turbine exhaust, whereas combustion-derived
hydrocarbons are compounds that have undergone a partial chemical change in the turbine
combustor that falls short of complete conversion to carbon dioxide and water. Depending
on the fuel source, the exhaust HC species and composition can vary greatly. It has been
reported that, for aircraft turbine engines operating with jet A fuel, combustion-derived
ethylene, acyetlene, propylene, and formaldehyde accounted for a major portion (22 to 43
percent) of the nonmethane hydrocarbons (8). Fuel-derived, C7-C9 hydrocarbons represent
a large portion of the remaining NMHC in the exhaust. On the other hand, the NMHC in
the exhaust of natural gas fired turbines are usually reported to consist of fuel-derived
ethane and propane, with trace levels of combustion-derived formaldehyde, benzene, and
other substances. The requirements of a catalytic NMHC emissions abatement system can
vary widely as a result of these distinctly different NMHC compositions for turbines using
different fuels.
Except for C2-C5 paraffins (i.e., ethane, propane, butane, and pentane), the
conversion rates of NMHC compounds are controlled by the rate of gas mass transfer to the
catalyst surface when operating at temperatures greater than 250 C. These reactive, often
combustion-derived, hydrocarbons include alkenes, alkynes, aromatics, C+6 paraffins, and
partially oxygenated hydrocarbons. This conversion efficiency will depend primarily on their gas
105
ABATEMENT OF THE HYDROCARBON AND CO EMISSIONS FROM GAS TURBINE
phase diffusivities and, as in CO oxidation, on the geometric surface area of the honeycomb
catalyst. The conversion rates of reactive hydrocarbons will always increase with increasing
catalyst cell density, because the geometric surface area for reaction increasing.
However, the absolute conversion level for each species will depend on its diffusion
rate in the exhaust gas. In general, larger, heavier molecules (like C8 and C9 molecules) will
diffuse more slowly than smaller, lighter molecules such as ethylene.
The primary hydrocarbon types found in the exhaust of a natural gas fired
combustion turbine are light paraffins, and these are among the less reactive molecules
for oxidation. Methane, ethane, propane, butane, and (to a lesser extent) pentane) require
special catalysts, higher temperatures, or both before they can be destroyed using practical
volumes of catalyst in a combustion turbine exhaust.
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AIR POLLUTION CONTROL TECHNOLOGIES
There are three primary sources of catalyst poisons and contaminants in the
exhausts of co-generation combustion turbines: fuel contaminants, boiler leaks, and turbine
lubricants. Of the three, sulphur oxides from liquid fuels are the most common. Poisoning
from boiler feed additives and turbine lubricants can be much more severe.
At temperatures below about 300 C, SO2 chemisorbs on to the active metal sites
and inhibits the oxidation of both CO and HC (12). It is for this reason that most processes
operate above 300 C . Notably that SO3 formed from the oxidation of SO2, can react with
alumina leading to formation of Al2(SO4)3, which further deactivates the catalyst. Catalysts
are therefore formulated to minimize SO3 production. New washcoats have been developed
that adequately disperse the active catalytic
metals but are unreactive towards SO3.
Catalyst contamination from sources such as turbine lubricant and boiler feed
water additives (e.g., Zn, P, Ca) is usually much more sever than deactivation by sulphur
compounds in the turbine exhaust. This is because these materials irreversibly mask the
catalyst surface. Therefore, catalyst regeneration remains the best option for maintaining
good conversion in the dirtiest environments. Commercial experience led to the development
of catalyst regeneration procedures that can restore most of the original catalyst activity,
however this requires shat down of the process.
8.4 References
1. Walsh P. and Fletcher P., Gas Turbine Performance, Second Edition, Blackwell Publishing House, 2004.
2. Magnus Johansson E. et al. in Catalytic Combustion for Gas Turbine Applications, Chapter 6, Catalysis,
Volume 14, The Royal Society of Chemistry, 1999.
3. Dalla Betta R.A., Catal. Today, 47 (1997) 369-375.
4. Sadamori H., Catal. Today, 47 (1999) 325-338.
5. Speronello, B., Chen, J., and Heck, R. 1992. A Family of Verstile Catalyst Technologies for NOx and CO
Removal in CO-Generation. 92-109.06, 85th Annual Awma Meeting, June 21-26, 1992, Kansas City, Mo.
6. Chen, J., Speronello, B., and Heck, R. 1993. Catalytic Control of Unburned Hydrocarbon Emissions in
Combustion Gas Turbine Exhaust. 93-mp 7.03, 8th Annual AWMA Meeting, june, 1993, Denver, Co.
7. Pereira, C., Gulian, F., Czarnecki, L., Rieck, J. 1990. Dual Function Catalyst for Clean Gas Application. 90-
105.6, 83rd Annual AWMA Meeting, June 24-29, 1990, Pittsburgh, pa.
8. Spicer, C., Holdren, M., and Smith, D. 1990. Chemical Composition of Exhaust from Aircraft Engines. Gas
Turbine and Aeroengine Congress and Exposition, June 11-14, 1990, Brussels, Belgium.
9. Pereira, C., Plumblee, K., and Evans, M. 1988. Camet Metal Monolith Catalyst System for Cogen Applications.
2nd International Symposium on Turbomachinery. Combined Cycle Technologies and Cogeneration. IGTI-Vol 3.
Ed. G. Serovy and T. Fransson, Book No. 1002705.
10. Centi G., Ciambelli P., Perathoner S., Russo P., Cat. Today, 75 (2002) 31-15.
11. http:\\www.engelhard.com/etg
12. Heck R.M. and Farrauto R.J., Catalytic Air Pollution Control, Wiley-Interscience; 2 edition, New York (2002).
107
AIR POLLUTION CONTROL TECHNOLOGIES
109
OZONE CONTROL STRATEGIES
stations are increasingly using special nozzles at the pumps to recapture gasoline vapours,
and vehicle inspection programs are being improved to reduce emissions.
Great effort (3-5) has been devoted to the development of ozone abatement
technology suitable for application in Jet Aircraft. Adsorption and thermal and catalytic
decompositions have been investigated so far. The amount of adsorbent (e.g., carbon)
required for such applications would weight too much for practical use. High fuel penalty
limits the use of thermal processes which require high temperatures. Catalytic decomposition
occurs at much lower temperature and is more acceptable. Therefore, the majority of the
aircrafts equipped for ozone abatement, use a catalyst to decompose ozone. (2)
Both precious and base metals were explored for this application. It must be
noticed that, due to the ozone high oxidation capability, it has been observed a rapid
deactivation of many catalytic materials after a short exposure. This caused considerable
problems in early testing because many materials looked good on bench tests but failed in
the aircraft after a relatively short time. (4). The most effective catalytic material is about 1
percent Pd on gama alumina supported on a high cell density ceramic or metallic monolith.
9.3 References
1. Pollution: Causes, Effects and Control, Harrison R. M. Ed., The Royal Society of Chemistry, Cambridge,
1996.
2. Heck R.M. and Farrauto R.J., Catalytic Air Pollution Control, Wiley-Interscience; 2 edition, New York (2002).
3. Couach O., Kirchner F., Jimenez R., Balin I., Perego S., van den Bergh H., Atmospheric Environment, 38
(2004) 14251436.
4. Heck R., Farrauto R., and Lee H., Cat.Today, 13 (1992) 43-85.
5. Galligan M.P. and Dettling J.C., United States Patent 5620672, 1997.
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AIR POLLUTION CONTROL TECHNOLOGIES
Rich Lean
0.68 0.95 1.22 1.50 l
Pollutant emisions (a.u.)
NO Engine power
HC
CO
10 14 18 22
Air : Fuel ratio, by weight
Figure 10.1: The effect of air-to-fuel ratio (w/w) on engine emissions (after ref. (8))
Tuning of the engine to rich feed gives the highest power output, which, however,
occurs at expenses of high fuel consumption. Under lean-conditions lower combustion
temperatures lead to lower NOx emissions, however, at ver y high A/F engine misfire occurs,
111
AIR POLLUTION FROM MOBILE SOURCES
leading again to high HC emissions. Under any A/F conditions catalytic abatement of
pollutants is needed to comply with the legislation limits. Only at stoichiometric conditions
appropriate amounts of reducing and oxidising agents are present in the exhaust to carr y
out simultaneously the catalytic reactions of NOx reduction and CO and hydrocarbon
oxidation.
Exhaust
Diesel engine Four stroke spark Four-stroke lean-burn Two-stroke spark-
components and
ignited-engine spark- ignited engine ignited engine
conditions a
NOx 350 - 1000 ppm 100 - 4000 ppm 1200 ppm 100-200 ppm
HC 50 - 330 ppmC 500 - 5000 ppmC 1300 ppmC 20000 - 30000 ppmC
CO 300 - 1200 ppm 0.1 - 6 % 1300 ppm 1-3%
O2 10-15 % 0.2-2 % 4 - 12 % 0.2 - 2 %
H2O 1.4-7 % 10-12 % 12 % 10 - 12 %
CO2 7% 10-13.5 % 11 % 10 - 13 %
SOx 10 - 100 ppm b 15 - 60 ppm 20 ppm 20 ppm
PM 65 mg/m3
Temperatures rt - 650 C rt - 1100 C c rt - 850 C rt - 1000 C
(A/F) e
1.8 (26) 1 (14.7) 1.16 (17) 1 (14.7) d
a
N2 is remainder. b For comparison: diesel fuels with 500 ppm of sulphur produce
about 20 ppm of SO2. c Close coupled catalyst. d Part of the fuel is employed for scavenging
of the exhaust, which does not allow to define a precise definition of the A/F. e defined as
ratio of actual A/F to stoichiometric A/F, = 1 at stoichiometry (A/F = 14.7) .
In the past, exhaust emission standards (limits) have been set in most industrialised
countries for passenger cars, light-duty trucks and heavy-duty trucks (gasoline and diesel
engines). For the gasoline engines, nowadays, the requirements are to reduce emissions
by about or even more than 95% in comparison to typical amount of pollutants emitted by
late-sixties automobiles with uncontrolled emissions. As an example, under the European
limits the uncontrolled CO emissions in the late sixties were around 60 g of CO km-1, which
should drop, according to an EU proposal, down 1.0 g km-1 by year 2005. This is equivalent
to a 98% reduction of the CO emissions. Similarly, a very restrictive situation is foreseen for
HC emissions. Both lowering of the limits down to 0.10 g km-1 and the inclusion of the cold
start in the vehicle test are important targets which need to be fulfilled.
The Environmental Protection Agency (EPA) established a federal Test Procedure
(FTP) simulating the average driving conditions in the U.S in which CO, HC, and NOx would
be measured. The FTP cycle was conducted on an engine dynamometer and included
measurements from the automobile during three conditions: (i) cold start, after the engine
was idle for eight hours, (ii) hot start, and (iii) a combination of urban and highway, driving
conditions. Separate bags would collect the emissions from all three modes, and a weighing
factor was applied for calculating the total emissions.
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AIR POLLUTION CONTROL TECHNOLOGIES
The need to control engine emissions according to Clean Act Air, recent
amendments have set up more stringent requirements for automotive emissions (2). The
catalysts will be required to last 100,000 miles for new automobiles after 1996. Furthermore,
the amendments (contingent on tier 2 standards to be set by environmental protection
agency) reduce nonmethane hydrocarbon (NMHC) emissions to a maximum of 0.125 g/mile
by 2004 (down from 0.41 g/mile in 1991), carbon monoxide to 1.7 g/mile (down from 3.4
g in 1991), and nitrogen oxides to 0.2 g/mile (down from 1.0 g).
Engine manufactures have explored a wide variety of technologies to meet the
requirements of the Clean Air Act. Catalysis has proven to be the most effective passive system.
The major worldwide suppliers of automotive catalysts are Engelhard, Johnson Matthey,
Degussa, and Allied Signal. As the automobile engine has become more sophisticated,
the control devices and combustion modifications have proven to be very compatible with
catalyst technology, to the point where today engineering design incorporates the emission
control unit and strategy for each vehicle.
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AIR POLLUTION FROM MOBILE SOURCES
Fig. 10.2: Effect of A/F ratio on the conversion efficiency of three-way catalysts. (adapted from ref 4)
To obtain an efficient control of the A/F ratio the amount of air is measured and
the fuel injection is controlled by a computerised system which uses oxygen sensors ()
located at the inlet of the catalytic converter. The signal from the sensor is used as a
feed-back for the control loop. A second additional sensor is mounted at the outlet of the
catalytic converter (Fig. 10.3) .
Figure 10.3: A picture of a modern TWC/engine/oxygen sensor () control loop for the engine exhaust control
(Courtesy of Mr. R. Crevatin, University of Trieste)
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AIR POLLUTION CONTROL TECHNOLOGIES
This configuration constitutes the basis of the so called engine on-board diagnostics
(EOBD). By comparing the oxygen concentration before and after the catalyst, A/F fluctuations
are detected. Extensive fluctuations of A/F at the outlet signal system failure. This EOBD
arrangement implicitly assumes that only a narrow A/F window at stoichiometric point is
the fingerprint of an effective TWC type of system. The location of the catalytic converter is
another critical point which determines the conversion efficiency. TWCs typically feature a
so-called light-off type conversion vs. temperature behaviour. This curves is characterised by
conversion which steadily increases from 0 to 100 % conversion, the temperature of 50 % of
conversion being indicated as the light-off temperatures. TWCs are characterised by a light-
off temperature around 250-350C (Fig. 10.4) (4). This means that an under-floor catalyst
is heated above the light-off temperature within 90-120 s. Differently, when the catalyst is
closely coupled to the engine (CCC close-coupled catalyst) the heating time typically drops
down to 10-20 s. This dramatically affects vehicle emissions immediately after the start
up of the engine. The ULEV (Californian ultra low emissions vehicle) limit (0.064 g of HC
emitted/km) is typically surpassed within 40 s after the engine start-up (9). This requires
for an almost instantaneous heating up of the converter to achieve the required >95-98%
conversion. As a consequence of this location of the catalyst, temperatures up to 1100C
are easily met by a CCC.
100
CO
Conversion / %
HC
50
NO
0
200 300 400 500
Temperature / C
It must be realised that the latest US and European legislation (EURO phase V
and US TIER II) limit for automotive emissions require application of the CCCs and EOBD
technologies on the vehicles in order to meet the emissions standards. A high durability is
also an important requirement for the present and future TWCs, for example a durability up
to 130.000 miles of the catalyst will be demanded by US tier II regulations in 2004. It should
be considered that if a significant part of the vehicles fails the periodical exhaust emission
controls, converter replacement becomes mandatory for a vehicle manufacturer. Accordingly,
an extremely efficient and robust catalyst is required for future vehicle applications.
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AIR POLLUTION FROM MOBILE SOURCES
fact, high conversion must be achieved in the converter and therefore the catalyst works
under conditions where severe mass and heat transfer limitations apply. Typically, both
metal and ceramic monoliths are employed nowadays. The major advantage of the metallic
substrate is that the wall thickness is limited by the steel rolling mills capabilities, not
strength. In a typical automotive 400 cell/inch2 application, the frontal flow area in a ceramic
monolith is 69% open (31% closed), while the metallic version has 91% open area. This is
due to the higher wall thickness of ceramic monoliths (0.007 inch (0.178mm)) compared to
metallic ones (0.002 inch (0.050mm)). However, even in this field there has been a strong
improvement of the technology, cell densities as high as 900 cell/inch2 or even higher are
now commonly available on the market for both types of monoliths. Traditionally, cordierite
monoliths have been employed quite extensively, primarily due to their lower production cost.
However, a major advantage of the metal monoliths resides in their high thermal conductivity
and low heat capacity which allow very fast heating of the CCCs during the phase-in of the
engine, minimising the light-off time.
Figure 10.5: Diagram of a typical car converter (1) monolith and (2) metallic honeycomb (adapted from ref 4)
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AIR POLLUTION CONTROL TECHNOLOGIES
Al2O3 The choice of Al2O3 as carrier is dictated by the necessity of increasing the
surface area of the honeycomb monolith which is typically below 2-4 m2 l-1, where the volume
is that of the honeycomb (13). This does not allow achievement of high NM dispersion.
Alumina is chosen due to its high surface area and relatively good thermal stability under
the hydrothermal conditions of the exhausts. In most of the studies -Al2O3 is employed due
to its high surface area with respect to other transitional aluminas (14), however, also other
high temperature aluminas such as - and -Al2O3 can be employed for high temperature
applications such as in the CCCs because of their higher thermal stability compared to -
Al2O3. Since temperatures above 1000C can be met in the TWCs, stabilisation of transition
aluminas is necessary to prevent their transformation to -Al2O3, which typically features
surface areas below 10 m2 g-1. A number of stabilising agents have been reported in the
literature, lanthanum, barium, strontium, cerium and, more recently, zirconium oxides or
salts being the most investigated (15-22). These additives are impregnated onto -Al2O3 or,
sometimes, sol-gel techniques are employed to improve the stability of the surface area.
For a detailed discussion of these roles and their relative importance we refer the
reader to earlier literature (4,24,25).
Among the different roles of CeO2 in TWCs, the OSC is certainly the most important
one, at least from the technological point of view. This is due to the fact that unambiguous
relationships between the TWC activity and OSC performances have been established (26).
Starting from 1995, CeO2-ZrO2 mixed oxides have gradually replaced pure CeO2 as OSC
materials in the TWCs (27), even though some low purity CeO2 materials may be employed
for less demanding TWC technologies (28). The principal reason for the introduction of CeO2-
ZrO2 mixed oxides in place of CeO2 is due to their higher thermal stability (27,29-32).
Noble metals Obviously NMs represent the key component of the TWC, as the
catalytic activity occurs at the noble metal centre. However, we purposely discuss the
aspects related to the NM at this point, since its interaction with the various components of
the washcoat critically affects the activity of the supported NM.
In principle, the first aspect to be considered is the choice of the NM and its
loading in the washcoat. Rh, Pd an Pt have long been employed in the TWCs and there is a
general agreement about the specificity of Rh to promote NO dissociation, thus enhancing
the NO removal (24,36-38), even if alternative mechanistic pathways for NO reduction have,
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AIR POLLUTION FROM MOBILE SOURCES
also, been proposed (39-41). Pt and Pd are considered as metal of choice to promote the
oxidation reaction, even though Rh also has a good oxidation activity. In particular, except
some initial use in 1975-76, Pd has extensively been added to TWC formulations starting
from mid 90s due to its ability to promote HC oxidation (9,10). In fact, better A/F control (42)
and modification of the support provided high NOx conversion, comparable to the traditional
Rh/Pt catalyst (43). The increase of the use of Pd in the TWC technology adversely affected
Pd market price, which is now comparable to that of Pt. In fact, there is a large demand for
Pd due to the fact that a straightforward way to increase the efficiency of the TWCs at low
temperatures, is that of increasing the NM loading, and particularly that of Pd, which for long
was the cheapest NM among the three ones employed (Figure 10.6).
10
2000
Million
oz 9
$ 8
per oz
1500 7
5
1000
4
500
2
0 0
1997 1999 2001 2003 1987 1992 1997 2002
Rh Pt Pd
On the other hand, use of high NM loading may favour sintering at high temperatures,
leading to deactivation of the TWCs, in addition to the fact that cost-effective TWCs are
required by the market. In summary, the choice and loading of the NM is a compromise
between the required efficiency of the converter and the market price of the NM; ideally a
car maker would prefer to have at the disposal a choice of TWCs with different NMs, which
would allow the best choice to be made according to price fluctuations of the NMs.
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AIR POLLUTION CONTROL TECHNOLOGIES
TWC preparation methods, etc. For example, when NM were supported on CeO2-ZrO2 mixed
oxides and aged at high temperatures under redox conditions, encapsulation of Pd and Rh
within the pores of the support occurred, while it did not occur for Pt (45).
Albeit it received relatively scarce consideration (46), the issue of sulphur poisoning
of TWC needs some consideration. As above discussion inclusion of CeO2-based promoters
into the washcoat considerably enhances the conversion efficiency of the TWCs. On the
other hand, both CeO2 and ZrO2 are known to easily adsorb SOx species: sulphated ZrO2 is a
well known solid acid catalyst (47). Investigation of reduced and oxidized CeO2 revealed that
SO2 is adsorbed under various forms, both surface and bulk-type of sulphates being formed
(48,49) and may even modify the microstrucutre of the CeO2-based oxide (50). Curiously,
under oxidizing conditions bulk sulphates decomposed by 600C whereas surface sulphates
persisted up to 700C (48). Use of reducing conditions favours elimination of sulphates as
H2S which can be easily detected as rotten-egg odour (51), particularly in the presence of
noble metal (52). The OSC of CeO2 is detrimentally affected by the presence of SO2, while
addition of ZrO2 to CeO2 increases the resistance of CeO2 to sulphur poisoning, albeit more
sulphur is adsorbed at the surface (46). This may be associated with the generally higher
OSC efficiency of the CeO2-ZrO2 mixed oxide compared to CeO2 and the possibility that ZrO2
acts as sulphur scavenger. Ni containing oxide are sometimes added to the washcoat in the
USA as sulphur scavengers while their use in Europe is prohibited.
A first possibility is that of collecting the HC emitted during the warm-up of the
converter in a HC trap, typically composed of hydrophobic zeolite. In an optimal trap, HC are
trapped at low temperatures and as the temperature is increased above 250-300C trapped
HC are released and converted on the TWCs (Fig. 10.7). A suitable trap must also feature
very high thermal stability under hydrothermal conditions, which often is not the case for
zeolite type of systems. We recall that temperatures as high as 850-900C may be reached
in the under-floor catalysts.
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AIR POLLUTION FROM MOBILE SOURCES
HC -
Catalyst HC retained by adsorber
adsorber
Warmed-up
The substrate, onto which the catalyst is deposited, is generally made from metal
so that, when an electric current is passed, it will heat up quickly. This brings the catalyst to
its full operating temperature in a few seconds.
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AIR POLLUTION CONTROL TECHNOLOGIES
The diesel engine, invented in the late 19th century by Dr. Rudolf Diesel, is the
most energy efficient power plant among all type of internal combustion engines known today.
This high efficiency translates to good fuel economy and low greenhouse gas emissions.
Other diesel features that have not been matched by competing energy conversion machines
include durability, reliability, and fuel safety. The downsides of diesels include noise, low
specific power output, NOx and PM emissions, and high cost (61).
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AIR POLLUTION FROM MOBILE SOURCES
Driving behind a diesel bus or truck, whether on a highway or in the city, often is
an unpleasant experience because of its emissions. The black smoke, or soot, is the most
visible emission, but other, less visible pollutants are also present. The emissions from a
diesel engine are composed of three phases: solids, liquids, and gases. The combined solids
and liquids are called particulates, or total particulate matter (TPM), and are composed of
dry carbon (soot), inorganic oxides (primarily as sulfates), and liquids. When diesel fuel
is burned, a portion of the sulphur is oxidized to sulphate, which, upon reaction with the
moisture in the exhaust, becomes H2SO4. The liquid are a combination of unburned diesel
fuel and lubricating oils, called the soluble organic fractions (SOF) or volatile organic fractions
(VOF), which from discrete erosols and/or are adsorbed within the dry carbon particles)
(62). Gaseous hydrocarbons, carbon monoxide, nitrogen oxides, and sulfur dioxide are the
constituents of the third phase.
In diesel engines, fuel is injected into the engine cylinder near the end of the
compression stroke. During a phase known as ignition delay, the fuel spray atomizes into
small droplets, vaporizes, and mixes with air. As the piston continues to move closer
to top dead center, the mixture temperature reaches the fuels ignition point, causing
instantaneous ignition of some pre-mixed quantity of fuel and air. The balance of fuel that
had not participated in premixed combustion is consumed in the rate-controlled combustion
phase, also known as diffusion combustion.
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AIR POLLUTION CONTROL TECHNOLOGIES
of SO2 can be oxidized to SO3 if the exhaust temperature exceed 450 C. The presence
of catalyst favors this oxidation process. Consequently, sulfuric acid and sulfate ions are
formed. Fuel sulfate and calcium of the lubrication oil may react to form gypsum, which may
strongly deactivate the particulate filter and/or hinder its regeneration. On the other hand,
emulsification with water may deplete soot formation. Metals such as nickel or manganese
charge the soot particles electrostatically and reduce agglomeration. The smaller particles
thus formed burn more easily. The characteristics of the fuel sach as viscosity, volatility,
thermal stability, aromatic content and C/H ratio also affect soot occurrence. Hydrocarbons
show the following smoking tendency:
Older type of diesel engine had relatively low injection pressure and operated
at low excess of air. Due to inefficient fuel injectors, a significant fraction of the fuel was
stacked to the walls of the combustion chamber as large fuel drops. This resulted in big
flakes of soot. Modern diesel engine works with redesigned fuel and air injectors and a large
excess of air. Therefore, an extremely efficient mixing of air and fuel is guaranteed, resulting
in nearly complete combustion and lower soot emissions.
Biodiesel
Vegetable oil was used as a diesel fuel as early as 1900, when Rudolf Diesel
demonstrated that a diesel engine could run on peanut oil. However, its use as a fuel
attracted little attention except in times of crisis such as during World War II and the energy
shortages of the 1970s. Increasing environmental concerns, expensive overproduction in
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AIR POLLUTION FROM MOBILE SOURCES
European agriculture and changes in government policies have resulted in expanded testing
and usage of biodiesel. The name biodiesel was introduced in the United States in 1992
by the National SoyDiesel Development Board (now the National Biodiesel Board), which
has pioneered the commercialization of biodiesel in the U.S. Biodiesel is defined as the
mono alkyl esters of long chain fatty acids derived from renewable lipid sources. Biodiesel
is typically produced through the reaction of a vegetable oil or animal fat with methanol in
the presence of a catalyst to yield glycerin and biodiesel (chemically called methyl esters).
Biodiesel has been registered with the US Environmental Protection Agency as a pure fuel
or as a fuel additive and is a legal fuel for commerce. The compression-ignition engine has
certain advantages over spark-ignition engines and role of biodiesel is to contribute to the
longevity and cleanliness of diesel engines.
The use of biodiesel as alternative fuel present the following significant
advantages:
1. Biodiesel can be made from domestically produced, renewable materials.
2. Biodiesel is the only alternative fuel that runs in any conventional, unmodified diesel
engine. It can be stored anywhere that petroleum diesel fuel is stored.
3. Biodiesel can be used alone or mixed in any ratio with petroleum diesel fuel. The most
common blend is a mix of 20% biodiesel with 80% petroleum diesel, or B20.
4. The life cycle production and use of biodiesel produces approximately 80% less
carbon dioxide emissions. This is very important in view of the control of the green-
house effect.
5. Combustion of biodiesel provides over a significant reduction in total unburned
hydrocarbons and an almost complete elimination of sulphur dioxide. Biodiesel
further provides significant reductions in particulates and carbon monoxide than
petroleum diesel fuel. However, biodiesel provides a slight increase or decrease in
nitrogen oxides depending on engine family and testing procedures.
6. Biodiesel is 11% oxygen by weight and contains no sulphur. The use of biodiesel
can extend the life of diesel engines because it is more lubricating than petroleum
diesel fuel, while fuel consumption, auto ignition, power output, and engine torque
are relatively unaffected by biodiesel.
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AIR POLLUTION CONTROL TECHNOLOGIES
has a higher viscosity than conventional diesel and therefore becomes less useful at lower
temperatures. This limits its use in Canada, the northern U.S. and much of Europe. In these
areas, biodiesel is marketed as an additive in a five to ten percent blend with conventional
diesel fuel.diesel engines.
Dimethyl Ether
Dimethyl ether (DME) can be made from a variety of fossil feedstock including
natural gas and coal as well as from renewable feedstock and waste. When used as a
diesel fuel, DME offers NOx and PM emission benefits. Emissions of CO and HC which may
increase with DME can be easily controlled by an oxidation catalyst. Energy efficiency of DME
is lower than that of diesel but higher than that of methanol/gasoline engines.
Diesel emission are clearly more complex than those of gasoline engine and
hence, their catalytic treatment is more complicated and requires new technology.
The popularity of diesel engines is derived primarily from their fuel efficiency
relative to the gasoline spark-ignited engine. Diesel operate very lean of stoichiometric,
with air-to-fuel ratios greater than about 22. They have good fuel economy, producing less
CO2. It is not uncommon for a diesel engine to have a life of 1 million miles, or about
10 times that of the gasoline engine. The diesel fuel and air mixture is highly composed,
raising the gas temperature to the point of combustion. Its lean nature results in a cooler
combustion with less gaseous NOx, CO, and HC emissions than its gasoline counterpart.
The design of the combustion process, however, results in high particulate emission levels.
In the past few years, engine manufactures have made great progress in redesigning the
engine (fuel injectors, timing, and so on) to minimize particulate emissions (63). The units
of measurement for particulates are grams per brake horsepower generated in an hour, or
g/bhp-h. For example, in 1986, particulate emissions from a typical diesel truck engine were
0.6/bhp-h. By 1990, manufacturers had redesigned the engine to reduce the particulates
to 0.25 g/bhp-h. In the U.S, emissions are measured over a standardized Federal Test
Procedure (FTP), The FTP simulates U.S. truck driving conditions. The Clean Air Amendment
of 1990 requires that by 1994 particulate emission be reduced to 0.1 g/bhp-h for truks and
no grater than 0.07 g/bhp-h for buses. This is where catalytic after- treatment can be used
effectively to bring engines into compliance with the standards (64).
Diesel emission control is being addressed worldwide. In the U.S., Europe, and
Japan, essentially all trucks and buses operate with diesel-fueled engines. In Europe, the
favorable price of diesel fuel relative to gasoline has resulted in a large number of diesel
fueled passenger cars. Trucks are used to ship goods; buses to transport groups of people
(usually within urban areas), and passenger cars are utilized for individual or small groups in
both urban and rural locations. Consequently, the allowable emissions standards differ for
each application. Furthermore, the terrain in the U.S., Japan, and Europe differ sufficiently
that the test conditions must reflect local driving habits. Each vehicle must specific emission
standards as measured in standardized driving cycles that reflect the duty cycle anticipated
for the particular engine. Table 10.2 summarizes current and proposed emission standards
worldwide. In Europe, passenger cars must meet standards reflecting both urban (ECE)
conditions and high-speed extra urban driving (EUDC). For European heavy-duty truck
applications, a 13-mode steady-state test with various loads/torques and speed is utilized.
This test puts emphasis on the high-temperature performance of the catalyst, reflecting high
load conditions. At such high temperatures, minimum generation of sulphate by catalytic
oxidation of gaseous SO2 becomes the most demanding requirement.
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AIR POLLUTION FROM MOBILE SOURCES
U.S. truck: HD FTP Transient Cycle, g/bhp-h. Euro truck: R-49 13 Mode. Euro car:
Cycle A, g/km. DI=Dir. Inj. Japan car: 10 Mode, g/km.
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AIR POLLUTION CONTROL TECHNOLOGIES
consumption. EGR control systems, utilizing open or closed loop control layouts, have to
provide precise EGR rates and proper A/F ratios in order to achieve their NOx reduction
targets while minimizing PM and fuel economy penalty. Even more precise A/F ratio control
is possible with variable geometry turbochargers and electrically driven chargers. EGR,
especially in uncooled configuration, in conjunction with high engine loads and aged lube
oils may also cause premature engine wear.
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AIR POLLUTION FROM MOBILE SOURCES
Two groups of catalyst systems are known for the reduction of NOx with hydrocarbons:
a copper substituted zeolite ZSM5 catalyst, which is active at high temperatures, and a
platinum/alumina catalyst, exhibiting low temperature activity. Both catalysts have narrow
operating temperature windows, resulting in only a limited NOx reduction efficiency, and
exhibit other problems. Some lean NOx catalysts have been commercialized, primarily to
provide small deNOx functionality in diesel oxidation catalysts. (4)
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AIR POLLUTION CONTROL TECHNOLOGIES
Due to the limited success of hydrocarbons as efficient reducing agent under lean
conditions, the use of urea as an alternative reducing agent for NOx from heavy duty diesel
vehicles has received attention. Selective catalytic reduction of NOx with NH3 in presence of
excess of O2 is a well implemented technology for NOx abatement from stationary sources
(70). Typically vanadia supported on TiO2, with different promoters (WO3 and MoO3) are
employed in monolith type of catalysts. A sketch of an arrangement for the urea based NOx
abatement technology is shown in Figure 10.10. Typically the urea solution is vaporised and
injected into a pre-heated zone where hydrolysis occurs according to the reaction :
H 2 N CO NH 2 + H 2 O CO2 + 2NH 3
Ammonia then reacts with NO and NO2 on the reduction catalyst via the
following reactions:
4 NO + 4 NH 3 + O2 4 N 2 + 6 H 2 O
6 NO2 + 8 NH 3 7 N 2 + 12 H 2 O
This approach has proved to be quite successful and high NOx (up to 80%) could be
achieved on Heavy Duty (HD) diesel engines under driving conditions, even after reasonably
high mileages (200.000-300.000 km), the activity decreased to about 75-80% of the initial
value after over 500.000 km (71,72).
Figure 10.10: A typical arrangement for abatement of NOx from a heavy futy diesel engine using urea as reducing
agent (from ref 4)
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AIR POLLUTION FROM MOBILE SOURCES
catalyst volume of 1:3 is typically employed for the urea-SCR systems that may represent
a serious problem in compact LD vehicles. Clearly an important improvement of the
catalytic performances is needed before such systems can be effectively considered for LD
application.
NOx adsorbers (traps) are the newest control technology being developed for partial
lean burn gasoline engines and for diesel engines (4). The adsorbers, which are incorporated
into the catalyst washcoat, chemically bind nitrogen oxides during lean engine operation.
After the adsorber capacity is saturated, the system is regenerated, and released NOx is
catalytically reduced, during a period of rich engine operation (Figure 10.11) . Typically a
Pt/BaO/Al2O3 catalyst is used to store NOx under oxidising conditions as adsorbed nitrate
species, which are then released and reduced on a traditional TWC by temporarily running
the engine under rich conditions.
Figure 10.11: Principle of operation of a NOx adsorber: NOx are stored under oxidizing conditions (1) and then
reduced on a TWC when the A/F is temporarily switched to rich conditions
Wall-Flow Monoliths
Wall-flow monoliths became the most popular diesel filter design. They are derived
from flow-through catalyst supports where channel ends are alternatively plugged to force the
gas flow through porous walls acting as filters. Wall flow monoliths are made of specialized
ceramic materials such as cordierite and silicon carbide. A number of mechanical and
thermal properties have been defined to characterize and compare different monoliths.
Filters of different sizes have been developed and are available as standard products.
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AIR POLLUTION CONTROL TECHNOLOGIES
Diesel filter systems are designed by combining filter materials with regeneration
methods. The biggest challenge in the system design is to ensure adequate regeneration
and durability. Filters must not be exposed to excessive thermal stress during regeneration
to avoid filter media failure. Based on the principle of regeneration, filter systems are
classified into passive and active. Considering low exhaust temperatures in many diesel
applications, both light- and heavy-duty, most future filter systems are likely to include some
active strategies to support regeneration.
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AIR POLLUTION FROM MOBILE SOURCES
Regeneration period
(1) Burner on
(2)
Working period
Burner off
Figure 2 10.12: Principle of filter operation (1) and filter re-generation (2) for a soot removal system, using fuel
powered burners. (adapted from ref 4)
Figure 10.13: The working principle of the continuously regenerating particulate trap
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AIR POLLUTION CONTROL TECHNOLOGIES
133
AIR POLLUTION FROM MOBILE SOURCES
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AIR POLLUTION CONTROL TECHNOLOGIES
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32. Terribile D., Trovarelli A., Llorca J., de Leitenburg C., and Dolcetti G., Catal. Today 43 (1998) 79.
33. Ranga Rao G., Kaspar J., Di Monte R., Meriani S., and Graziani M., Catal. Lett. 24 (1994) 107.
34. Fornasiero P., Di Monte R., Ranga Rao G., Kaspar J., Meriani S., Trovarelli A., and Graziani M., J. Catal. 151
(1995) 168.
35. Vlaic G., Fornasiero P., Geremia S., Kaspar J., and Graziani M., J. Catal. 168 (1997) 386.
36. Oh S.H., Fisher G.B., Carpenter J.E., and Goodman D.W., J. Catal. 100 (1986) 360.
37. Taylor K.C. and Schlatter J.C., J. Catal. 63 (1980) 53.
38. Taylor K.C., Catal. Rev. -Sci. Eng. 35 (1993) 457.
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43. Summers J.C. and Williamson W.B., Environmental Catalysis, (Armor J.N. Ed.), Chap.9, pp.95-113,
Washington, D.C., American Chemical Society, 1994.
44. Beck D.D., Sommers J.W., and Di Maggio C.L., Appl. Catal. B Environ. 11 (1997) 273.
45. Graham G.W., Jen H.W., Chun W., and McCabe R.W., J. Catal. 182 (1999) 228.
46. Boaro M., deLeitenburg C., Dolcetti G., Trovarelli A., and Graziani M., Top. Catal. 16 (2001) 299.
47. Song X.M. and Sayari A., Catal. Rev. -Sci. Eng. 38 (1996) 329.
48. Waqif M., Bazin P., Saur O., Lavalley J.C., Blanchard G., and Touret O., Appl. Catal. B Environ. 11 (1997)
193.
49. Overbury S.H., Mullins D.R., Huntley D.R., and Kundakovic L., J. Phys. Chem. B 103 (1999) 11308.
50. Nelson A.E., Yip J., and Schulz K.H., Appl. Catal B Environ. 30 (2001) 375.
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Ed.), pp.139-152, Amsterdam, Elsevier, 1991.
52. Bazin P., Saur O., Lavalley J.C., Blanchard G., Visciglio V., and Touret O., Appl. Catal. B Environ. 13 (1997)
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53. Lafyatis D.S., Ansell G.P., Bennett S.C., Frost J.C., Millington P.J., Rajaram R.R., Walker A.P., and Ballinger
T.H., Appl. Catal. B Environ. 18 (1998) 123.
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55. Kaspar J., Di Monte R., Fornasiero P., Graziani M., Bradshaw H., and Norman C., Top. Catal. 16 (2001)
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72 (2002) 145.
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60. Haruta M. and Date M., Appl. Catal A. Gen. 222 (2001) 427.
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62. Neeft J.P.A., Makkee M., Moulijn J.A., Appl. Catal. B 8 (1996) 57.
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65. Beckmann R., Engeler W., Mueller E., Engler B., Leyrer L., Lox E., and Ostgathe K. SAE Paper 922330
(1992).
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57-69 (1993).
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11 Appendices
The web is getting a more and more important tool for fast and efficient collection
of information on any topic, including scientific and technological aspects. Nevertheless,
the huge and increasingly amount of information can generate a confusion and inadequate
selection of the priorities. Furthermore, the problem of absence of peer review process for
most of the sources, can lead to superficial and sometimes wrong interpretations. We offer
here a few suggestion on web site, which, in our opinion, can provide useful information
regarding the topic of Air Pollution.
The web site of the European Union offers many information on environment
(http://europa.eu/pol/env/index_en.htm) and specifically also on air pollution (http://
europa.eu/scadplus/leg/en/s15004.htm).
The web site of the Organisation for Economic Co-operation and Development
(OECD) (http://www.oecd.org) is also useful to collect information on environment at http://
www.oecd.org/topic/0,2686,en_2649_37465_1_1_1_1_37465,00.html.
The International Center for Environmental Technology Transfer has an useful web
site at http://www.icett.or.jp
The web site www. cleanair.org provides information on air pollution worldwide..
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APPENDICES
11.2 Glossary
Absorption
The transfer of molecules from the bulk of the gas to a liquid surface, followed by diffusion of
these molecules to the bulk of the liquid.
ACFM The acronym for actual cubic feet per minute, which is the actual gas flow rate expressed in the
American Engineering system of units. ACFM is a measure of the volume of gas that passes a
given point during a one-minute period.
Acid Gas Scrubbing System
A wet scrubbing system capable of achieving high acid gas removal efficiency by introducing water,
caustic, or hydrated lime into the gas stream.
Adsorbs The adhesion of a substance to the surface of a solid or liquid.
Adsorption
The process whereby vapor phase compounds in the gas stream pass through a bed or layer of
highly porous material (adsorbent). The vapor phase compounds diffuse to the surface of the
adsorbent and are retained due to weak attractive forces.
Aerosols
The suspension of solid or liquid particles in the atmosphere.
Air Preheater
Indirect heat exchanger designed to transfer heat from combustion gas to the air stream added
to the combustion zone.
Air Toxics (or Hazardous Air Pollutants)
Pollutants that are known to cause or suspected of causing cancer or other serious health effects,
such as developmental effects or birth defects.
Attainment Area
An area that meets the air quality standard for a criteria pollutant (under NAAQS).
Autoignition Temperature
The minimum temperature at which a substance ignites without application of a flame or spark.
Baghouse
This term is often used interchangeably with the term filtration systems. However, it is applicable
only to pulse jet, cartridge, reverse air, and shaker-type filtration systems. The term baghouse
does not have any clear meaning for HEPA filtration systems.
Bag Blinding
Conditions where the particles (dust) become embedded in the fabric filter over time and are not
removed by the bag cleaning process.
Barometric Pressure
The total pressure exerted by the atmosphere. This term is synonymous with atmospheric pressure.
Bottom Ash
Incombustible matter resulting from combustion that does not leave as fly ash.
Burners Out Of Service (BOOS)
An off-stoichiometric combustion modification for control of NOx performed by operating alternate
burners in the combustion zone as either fuel rich, air rich, or air only.
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AIR POLLUTION CONTROL TECHNOLOGIES
Clarifier
Vessel where particulate matter of higher density than the surrounding liquid is separated and
removed from the liquid by gravitational settling.
Collection Efficiency
A ratio of pollutants entering a control device versus pollutants leaving the device expressed as
a percent.
Combustion
The production of heat and light energy through a chemical process, usually oxidation. Products
of complete combustion include water and carbon dioxide; while, incomplete combustion can
yield partially oxidized organic compounds and carbon monoxide. Factors that promote complete
combustion include the proper fuel-air ratio, temperature range, and adequate amount of time for
the fuel and its by-products to complete the combustion reactions.
Combustion Particle Burnout
Particulate matter formed and released by the combustion of fossil fuels
Condensable Particulate Matter
Particulate matter, contained almost entirely within the PM2.5 classification that forms from condensing
gases or vapors. It forms by chemical reactions as well as by physical phenomena.
Condenser
A simple, relatively inexpensive device that normally uses water or air to cool and condense a
vapor stream.
Cyclone (Large Diameter)
A type of mechanical collector, usually ranging in size from one to six feet in diameter, that uses
a spinning movement of the gas stream to collect particles ranging in size from one-sixteenth to
more than 6 inches in diameter.
Cyclonic Separator
A mechanical collector that uses centrifugal force to drive particles to the wall of the device.
Desorption
The process of using low-pressure steam or hot nitrogen gas to remove compounds from an
adsorbent bed.
Dew Point
The temperature at which the partial pressure of a substance (in vapor form) equals the equilibrium
vapor pressure of the substance. At this temperature, a vapor begins to condense at a constant
pressure.
DRE The acronym for destruction and removal efficiency
Dry Scrubber
An air pollution control device used to remove an acid gas pollutant from a gas stream. The
pollutant is collected on or in a solid or liquid material, which is injected into the gas stream. A dry
scrubber produces a dry product that must be collected downstream from this control device.
Dust A mixture in air of irregular shaped mineral particulates in the size range from 1 to 200 m formed
by crushing, chipping, grinding or like operations or by natural disintegration of rock and soil.
Electrostatic Precipitator
A type of air pollution control system that uses high voltage fields to electrically charge and collect
particulate matter. The charged particles approach an electrically grounded collection plate and
accumulate as a dust layer, which is partially removed by mechanical rapping (hammers) on a routine basis.
Emission Sampling Train
Equipment usually consisting of (1) a sampling nozzle and probe, (2) filter and impingers for
collection of gaseous and/or particulate components, (3) flow meter and flow regulation devices,
and (4) a vacuum pump for collecting a representative sample of a gas stream.
EPA The acronym for environmental protection agency.
ESP The acronym for electrostatic precipitator.
Evaporative Cooling Tower
Equipment used to reduce the temperature of a gas stream. Fine droplets, injected into a vessel,
are evaporated as they absorb heat from the gas stream.
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APPENDICES
Fabric Filter
A filtration device using one or more filter bags, sheets, or panels to remove particles from a gas
stream.
Fan Drive
The way in which the motor shaft is linked to the fan wheel to transmit power and control speed.
Fine Particles
EPA classification of particles having aerodynamic diameters greater than 0.1 micrometer and
less than or equal to 2.5 micrometers.
Flue Gas Desulfurization (FSD)
The process by which sulfur is removed from combustion exhaust gas.
Fly Ash
Uncombusted particulate matter in the combustion gases resulting from the burning of coal and
other material.
FPD The acronym for flame photometric detection
Fuel NOx
Nitrogen oxides generated from the fuel or waste during combustion.
Fugitive Emissions
Emissions that escape from industrial processes and equipment.
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Overfire Air
An off-stoichiometric combustion modification for control of NOx where the lower burners operate
under fuel rich conditions and air injection nozzles located above these burners complete the
combustion process.
141
APPENDICES
Scrubbing Liquid
A liquid used to remove particulate or gaseous pollutants by absorption or chemical reaction
through contact with the gas stream.
of the treatment time (residence time). Space velocity has units of 1/seconds or 1/minutes.
SCWO for supercritical water oxidation.
Smoke A mixture in air of very fine particles formed by combustion or other chemical processes in the
some range from 0.01-1 m. The particles may be irregular in shape if formed of solid material or
they may be spherical if formed by condensation.
Spray-Dryer-Type Dry Scrubber
An air pollution control device for removing acid gases where an alkaline slurry is introduced into
the gas stream and the pollutants absorb into the droplets and react. The droplets dry in the gas
stream leaving particulate matter, which is collected by a downstream particulate control device.
Ultrafine Particles
EPA classification of particles having aerodynamic diameters less than or equal to 0.1
micrometer.
Venturi Scrubber
A type of wet scrubber that is usually highly efficient but requires a large amount of energy to
operate. (Wet scrubbers are air pollution control devices.) In venturi scrubbers, a scrubbing liquid
is introduced into the gas stream, which then passes through a contracted area of the scrubber at
a high velocity creating a high dispersion of fine droplets. These fine droplets capture the gaseous
and particulate pollutants.
VOC Volatile organic conpounds.
Wet Scrubber
A vessel used for removing pollutants from a gas stream by means of a liquid spray, liquid jet, or
liquid layer.
142