Optimal solutions to meet emission regulations, reduce pollution, and make profit from waste
Turning feedstock into valuable products, whether through chemical processing or hydroprocessing, is always linked to the formation of pollutants like sulfur, NOx (nitric oxide and nitrogen dioxide), CO (carbon monoxide) or VOC (volatile organic compounds). As emission regulations to protect our climate, health, and welfare continue to get tighter around the world, optimal emissions management is increasingly important for our customers.
With the emissions management solutions of our joint venture partner Haldor Topsoe, we help our customers meet regulations, reduce pollution, and make profit from waste. Haldor Topsoe provides specialist stationary catalytic solutions for cleaning the off-gases from heavy industry and power plants with more than 1,000 installations worldwide.
In addition to providing regulation compliant solutions for the optimal handling of sulfurous gases Ferrostaal Topsoe Projects ensures they also are economically feasible. Due to their high availability, energy efficiency and flexibility, the solutions are guaranteed to perform optimally. Haldor Topsoe's wet gas sulfuric acid (WSA) technology recovers sulfur from off-gases in the form of commercial-grade concentrated sulfuric acid, thus converting waste into a commercial product.
The WSA process is a wet gas catalytic process. The concentrated sulfuric acid is produced by condensation from a wet process gas. Drying of the process gas prior to treatment in a WSA plant therefore becomes superfluous, hence generation of waste water and loss of sulfur are avoided. The purpose of the first step in the process is to produce an SO2 gas at the operating temperature of the oxidation catalyst in the SO2 converter. If the sulfur in the feed is SO2, only a simple preheating is required. Other sulfurous feeds are oxidized to SO2 by combustion and then cooled to the optimum catalytic conversion temperature in a waste heat boiler. The excess heat from this operation is recovered as steam. The catalytic conversion of SO2 to SO3 takes place in one or more catalyst beds. Reaction heat is recovered between the catalyst beds by superheating of steam. After the last conversion step, the gas is cooled and the SO3 reacts with water vapor to form gas phase sulfuric acid. The process gas is finally cooled by a counter current flow of air in the proprietary WSA condenser. Clean gas exits at the top of the WSA condenser, and the sulfuric acid is collected in the bottom section from where it is cooled and sent to storage. Hot air generated in the WSA condenser may be used as preheated combustion air to ensure optimal energy efficiency.
NOx & CO removal (nitric oxide, nitrogen dioxide and carbon monoxide)
Meeting emission standards without compromising the performance or profitability of an industrial plant is a challenge that many of our customers are facing. Ferrostaal Topsoe Projects offers solutions for NOx and CO removal for stationary applications that are highly effective and reliable, offering reduction efficiencies up to 99 %, even when operating under severe conditions.
The SCR DeNOx process is designed to combine a performance that will meet the most stringent environmental regulation and at the same time at the lowest cost for the operator. Throughout the lifetime of the catalyst the operation will be stable and reliable for the widest range of fuels ranging from coal, gas, and oil to biomass and waste.
CO removal is of increasing importance. The process is offered either separately or together with DeNOx removal. Especially our new dual functioning catalyst provides NOx and CO removal in ONE catalyst requiring only a very small footprint and at low pressure drop - providing high economical benefits for the operator.
VOC removal (volatile organic compounds)
Regulatory pressure on volatile organic compounds (VOC) emissions has never been higher. Ferrostaal Topsoe Projects offers solutions that enable the abatement of VOCs from off-gasses, with reduction efficiencies above 99 % without creating any secondary pollutants. The solutions work in a safe, cost effective and environmentally friendly fashion. The VOC removal solutions further reduce, or even eliminate, the use of support fuel, which reduces energy and resource consumption, lowering operational expenditures for our customers.