Advanced Technology to

control PM, Nox, VOCs

in a cost effective
Manner….. Presented by :
1 SACHIN PANWAR
Table of Content
• Why Clean the flue gas ?
• Why VOCs, Nox, SOx, PM are Threat?
• Haldor Topsoe in Brief
• Topsoe Solution Range
• Catalytic Process Fundamental Steps
• Topsoe Environmental solution.
• Catalytic Filtration technology
• Conclusion

2
 Why Clean the Flue Gas?

3
Major Contributing Factors
For Air Pollution

4
Daily cycle of pollutant concentration

5
Why VOCs, NOx ,SOx, PM are threat?

• Forms ground level ozone (or smog)

• Triggers asthma attacks and cancer
• Contributes to acid rains

6
Haldor Topsoe in brief

• Established in 1940 by Dr. Haldor

Topsøe.
• Private 100% family-owned company.
• Market leader in heterogeneous catalysis
and surface science for over 70 years.
• Around 2,800 employees in 11 countries
across 5 continents.
• Headquarters in Lyngby, Denmark.
• Spends more than 10% of revenue on
R&D.
Headquartered in Denmark,
our 2,800 employees work with customers all over the globe

Locations:
Bahrain
Beijing
Buenos Aires
Cape Town S H
S E
P E
S
Copenhagen
Edmonton
S P
Houston E
Joinville S P

Kuala Lumpur S S E
Los Angeles
Moscow
New Delhi
S
Rio de Janeiro
Tianjin

H Headquarters
S

P Production P

S
E Engineering S

S Sales & Service

8
We provide a full range of products and services for a broad range of business

Chemical Processing Hydroprocessing Emissions Management

Ammonia
Syngas
Methanol
Hydrogen
SNG Naphtha
Sulfuric acid Kerosene Sulfur removal
Dimethyl ether Diesel NOx & CO removal
Formaldehyde VGO VOC abatement
Gasoline synthesis Resid Particulate filtration

Process design,
Engineering, & licensing + High-performance
catalysts + Proprietary
equipment + Business &
technical services

9
Catalytic Process- Fundamental steps

1. Step 2. Step 3. Step 4. Step 5. Step

Gas phase transport and Adsorption of Surface Desorption of Gas phase transport and
pore diffusion of educts educts reaction products pore diffusion of products

Reactant Products

+ +
10
Haldor Topsoe Solution
For Environment Protection
Technology to transform
sulfur pollutants into
sulfuric acid

Catalysts to clean the Technologiyto remove

vehicle exhaust nitrogen oxides

Technology to treat
volatile organic
compounds

11
Wet gas Sulfuric Acid
A process for cleaning sulfur containing streams under production of
concentrated sulfuric acid

Lean H2S gas WSA

Rich H2S gas Cleaned gas
SRU tail gas
HP Steam
SWS gas
SO2
SO3
Spent H2SO4
H2SO4

12
WSA process lay-out, H2S gas
Reaction:
H2SO4 (g) → H2SO4 (liq)

Superheated steam
Stack gas
Blower
Combustion air

SO2 Converter
BFW Blower
Steam Air
Drum Interbed
cooler
WSA
H2S gas Interbed Condenser
cooler

Combustor WHB Gas

cooler
Reaction:
Acid cooler
H2S + 1½O2 → SO2 + H2O
CW
Reaction: Reaction:
Product acid
SO2 + ½O2 → SO3 SO3 + H2O → H2SO4 (g)
13
 Topsoe Vanadium SCR for Indian automotive market

• Very good low temperature conversion • Proprietary substrate,

• Full-body, unlike coated SCR no dependancy on substrate
manufacturers
• Best in class dynamic response to transient
• Local engine test and production
conditions
planned
• Best in class sulfur tolerance, due to high
• Mechanical durability, simple canning
porosity substrate
• Low deactivation over time
• Lowest weight
• Zone coated ASC, if needed
• Available in diameters 7.5” - 17”
• Proven technology for
Euro IV/V/VI and Tier4i/f

14
Catalytic combustion process
General

VOC + O2 = CO2 + H2O

100
90
80
70
Conversion (%)

60
50
40
Carbon monoxide
30 Methanol
Toluene
20 Chlorobenzene
10 n-Hexane
Ammonia
0
0 50 100 150 200 250 300 350 400 450
Temperature (oC)

15
Oxidation catalyst portfolio
> 500 references

Type Application
CK- Cu-Mn Hydrocarbons, hydrocarbons with
302/322 oxygen and nitrogen. Silicon and
CKM-2x bromine resistant

CKM-
3324
CK-304 Pd Aromatics, CO, hydrogen,
CKM-3x, ammonia, short-chained alkanes
DNOC
CK-305 Cr Halogenated hydrocarbons
CK-395 Mn
CK-306 Cr-Pd Halogenated hydrocarbons, CO
CK-307 Pt All hydrocarbons, CO, sulphur
compounds (<200 ppm)
CK-428 Cu-Mn Sulphur compounds (>200 ppm),
16 Pt ammonia
 SCR DeNOx Technology
17
 Chemical Reaction

• 6 NO + 4 NH3 → 5 N2 + 6 H2O
• 6 NO2 + 8 NH3 → 7 N2 + 12 H2O
O2 makes the reaction faster
Me=Vanadium or Tungsten

Mechanism:
• Adsorptions mechanism
• Elay-Rideal mechanism
• Langmuir-Hinshelwood
mechanism
18
 Reaction mechanism
OH O
NH
(1) NH3 + V5+-OH ↔ V-ONH4 V V
3 H
+
H
N O
NO(g) H
(2) V-ONH4 + V=O ↔ V-ONH3-V4+-OH
O H H
O O N N

(3) NO + V-ONH3-V4+-OH
V- → N2 + H2O + V5+-OH - - H
+ V4+-OH V
O
V
HO OH

(4) 2V4+-OH ↔ H2O + + V=OV3+ V V

(5) O2 + 2V3+ → 2V=O

O

(6) H2O + V5+-OH ↔ V5+-OH3O

[ H H O
N N
N N O
H
H
OH O

V V
O

O O O
HO OH 1 /2 O 2
H 2O V V - -
V V
V V O O
O

19
DeNOx reaction mechanism

1. Diffusion of the reactants to the catalyst surface

2. Adsorption of NH3 on an active site
3. Reaction of NH3 with NOx
4. Diffusion of products back to the flue gas
5. Reoxidation of vanadium site

5
NH3 NO H2 O N2
O2
4
Laminar-
1 gas film
3
Catalyst
NH3
NH3 surface
NO
2 Catalyst
pore

20
DeNOx technology
General system layout
• Ammonia storage
• Ammonia evaporation
• Ammonia injection
• Flow stratification
Boiler flue gas
• Soot blowers
FT NOx inlet
SCR
• SCR reactor and catalyst Flue gas
signal
reactor
flow signal
• Control system FT
PC

FV
NH3
NH3
Evaporator

Dilution air
Cleaned gas
Blower NOx outlet
signal

21
 Topsoe DNX catalyst characteristics

• Corrugated honeycomb
• Open geometry
• Titania based and impregnated with vanadium and
tungsten
• High strength – fibre reinforced
• Very porous structure
• High poisoning resistance
• Low SO2 oxidation
• Thermal shock resistant
• Temperature range:
180°C – 555°C

22
DeNOx catalyst – product range

Channes size
 2.5-10.0 mm

Wall thickness
 0.4, 0.8 and 1.0 mm

Chemical compositions
 10 different to optimise
activity/SO2 oxidation

23
 Catalyst Modules

• Modular Design
• 0.25, 0.50, 0.75, 1.00 meter catalyst height
• 2 x 4 cassette standard design

24
 SCR process - Reactor

NOx (flue gas)

NH3

25
 DNX catalyst features
Easy loading

26
 Advantages of Topsoe DNX Catalyst & Technology

Topsoe Operating
Experience:
 Gas flows up to 2.7 million
Nm3/h.
 SOx contents up to 5% (vol.).
 Temperatures between 180
and 475°C.

27
Performance Sheet

S.No. Parameter Outlet

1. NOx, ppm <25

2. NH3 slip, mg/Nm3 @ 6% O2 dry <10

3. NH3 reagent consumption, Kg/hr Low

4. Pressure Drop, mmH20 (4 oC) 20

28
Reference

Topsoe DeNOx
Technology has
around ≈1200
references world wide
in different sectors:

29
 Catalytic Filtration Solution
30 Over View
Combining competences
Haldor Topsoe

NH3 NOx

SCR
HT DNX Series

Dioxins &
Furans

CO Filtration
Oxidation
HT CK Series Fabric Filters &
VOCs Filter Bags Dust/PM

HC
31
Technology

EnviroTexTM Catalytic filter bags

• Each bag consist of three fabric layers

(bags) which individually are impregnated

• High filtration efficiency

• Filter bag up to 464 F (240 deg. C)

• VOC, ammonia removal, and DeNOx at low

temperature Design T: 410-464 F (210-260 C)
Dimension: app. 20-40 feet (6-12m) length
• No poisoning of catalyst

32
Catalytic filter bag

33
Catalytic Filter Bag

34
Catalytic filter bag Catalyst

Fibers

35
Technology

TopFraxTM Catalytic ceramic filters

Design T: 410-752 F
• Each filter consist of a ceramic fiber based filter
(210-400 C)
impregnated with a catalyst in the filter wall (20 Dimension: 1-3m
length
mm thick)

• High filtration efficiency (<2 mg/Nm3)

• Up to 662 F (350 deg C) with present catalyst

(filter up to 900 deg. C)

• DeNOx, ammonia and VOC removal.

• No poisoning of catalyst
36
NOx and NH3 removal (SCR)

4 NO + 4 NH3 + O2 -> 4 N2 + 6 H2O

Off-gas Clean gas

NH3
H2O
NO
O2 N2 N2

Gasflow
NO
N2
H2O
O2
NH3
NO2
O2

Particulate matter (dust)

Catalytic filter bag
37
NOx and NH3 removal (SCR)

38
Removal of VOC’s / Organic HAP
CH2O + O2 -> CO2 + H2O
Off-gas Clean gas

H2O
VOC
O2 CO2
N2
O2 Gasflow
VOC
H2O N2

O2
VOC CO2

O2

Particulate matter (dust)

Catalytic filter bag
39 VOC = Volatile Organic Compound: CO, Toluene, Benzene, Formaldehyde etc.
HAP = Hazardous Air Pollutant
Removal of VOC’s / Organic HAP

40
Furan/dioxin removal

Off-gas Clean gas

H2O
Dioxin
O2 CO2
N2
O2 Gasflow
Furan
H2O N2

O2
Dioxin CO2
Furan HCl
O2

Particulate matter (dust)

Catalytic filter bag
41
CataFlexTM Catalytic filter bag principle

42
TopFraxTM Ceramic filter principle

43
 Schematic illustration of the catalytic filter bag
1. layer 2. layer 3. layer

Membrane

Catalyst Catalyst Catalyst

Dust VOC NOx NH3 CO Dust VOC NOx NH3 CO Dust VOC NOx NH3 CO Dust VOC NOx NH3 CO

44
Application of catalytic filtration Technology

• Biomass
• Glass plants
• Metal production (sintering)
• Roasting (Corn, cacao, cofee)
• Carbon black
Etc….

• Cement kilns • Power plants

• Waste incinerators • Chemical industry

45
 Overview – Legislation within Cement Manufacturing
mg/Nm3 @ 10 vol. % O2 (dry)

USA Germany China (Common) ¤ World (Financing)

Pollutant NESHAP/NSPS BImSchV 17 GB30485-2013 World bank
HCl 5 10 10 10
THC (TOC) 3.6 10* 10 10
SO2 94 50* 200 400
NOx 360 200 400 600
NH3 - 30 10 -
Hg 0.005 0.03 0.05 0.05
Dust 1.8 10 30 30

*) Exceptions for raw materials possible

¤) Cement plants co-processing waste in common regions. The key region limits are stricter.
46
Catalytic Filtration Solutions
-----------------------------------------------------------------------------------conclusion
• New cost efficient solution for removing gas emission along with particulate matter
• Making the plants staying in compliance with even the stringent regulations
• Saves up to 80% on CAPEX compared to existing solutions used today
• Saves operational cost (OPEX) compared to existing solution used today
• Saves foot print of the total installation compared to existing solution used today
• Targeting Waste to Energy, Boilers, Cement Plants, Glass Plants
• …and similar industries with a flue gas containing hazardous compounds and dust
• Removal of (separately or combined at the same time):
• NOx
• HAP (hazardous air pollutants)
• VOC (volatile organic compounds)
• CO
• Dioxin and Furans
47
• NH3
• Dust and particulate matter (PM)
• 48

48
Questions?

Sachin Panwar
Business Development Manager

sapa@topsoe.in