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Comprehensive Flue Gas Desulfurization Solutions
According to Chinese environmental protection requirements, steel companies need to control sulfur emissions to ensure compliance with emission standards.
It is recommended to adopt source control and perform precise desulfurization at the source of blast furnace gas. For more details, please refer to the "Special Introduction to Precise Desulfurization at the Source of Blast Furnace Gas."
When source control is not feasible, flue gas desulfurization can be implemented at various user points using end-of-pipe treatment methods.
The following flue gas desulfurization methods are end-of-pipe treatment options that can be selected based on the actual conditions of the owner:
1.Wet Desulfurization
Removes sulfur dioxide(SO2)
2.SDS Dry Desulfurization
Removes sulfur dioxide (SO2)
3.Fixed Bed Dry Desulfurization
Removes sulfur dioxide (SO2)
The fixed bed dry desulfurization method has the following advantages:
★ Lower initial investment, especially when including civil construction costs, as the investment for the fixed bed method is much lower than that for SDS dry desulfurization.
★ Low operating costs, as the overall resistance loss for the fixed bed method is smaller than that for the SDS dry method, resulting in lower power consumption and no need for heating or fuel medium.
★ The solid waste produced by the fixed bed dry method is calcium sulfate, which is easier to handle than the sodium sulfate solid waste from the SDS method.
★ The fixed bed dry method does not require heating of the flue gas, whereas the SDS method generally needs to increase the temperature to at least 150 degrees Celsius.
★ Small footprint.
★ The fixed bed desulfurization part requires almost no maintenance.
★ The fixed bed method allows for direct addition of denitrification agents within the tower for future nitrogen oxide treatment needs.
Therefore, we recommend using the fixed bed dry desulfurization method:
Calcium-Based Ultrafine Powder Direct Injection Technology
If SDS dry desulfurization is chosen, we recommend using calcium-based desulfurizing agents (calcium-based ultrafine powder) in a direct injection form to replace sodium bicarbonate. This can solve the following issues:
★ Addresses the supply shortage of sodium bicarbonate due to the increasing number of desulfurization projects, ensuring no impact on enterprise production.
★ Mitigates the problem of rising sodium bicarbonate prices and the consequent increase in operating costs for enterprises.
★ Eliminates the impact of flue gas temperature on desulfurization efficiency.
★ Resolves the issue of fluorine in the flue gas affecting integrated desulfurization, denitrification, and dust removal devices.
★ Higher flue gas moisture content (within a certain range) increases desulfurization efficiency.
★ Reduces initial investment and the increase in power consumption costs during operation.
★ The desulfurization byproducts are easy to handle, and our company can recycle them.
Wet Desulfurization Technology
★ Lowest initial investment; low operating costs.
★ High desulfurization efficiency, low resistance, strong adaptability, and high availability.
★ Good adaptability to working conditions, with the ability to flexibly adjust the amount of reagent added according to changes in operating conditions.
★ Can use various desulfurization reagents such as sodium alkali, alkaline wastewater (blast furnace slag water, slag quenching wastewater, cooling tower circulating blowdown water), and calcium alkali.
Therefore, considering the actual situation of steel companies, industrial wastewater can be considered as the water source for wet desulfurization, thereby saving on fresh water consumption. This fully utilizes the calcium, magnesium, and other ions rich in industrial wastewater.
Ca+ +SO2 --> CaSO3
CaSO3 + 1/2 O2 --> CaSO4
Mg+ +SO2 --> MgSO3
MgSO3 + 1/2 O2 --> MgSO4
The treated wastewater can directly enter the existing wastewater treatment system without adding new wastewater.
If calcium and magnesium ions are insufficient, to ensure desulfurization efficiency, alkali solution needs to be added to supplement alkalinity.
2NaOH + SO2 --> Na2SO3 +H2O
Na2SO3 + 1/2O2 --> Na2SO4
Comprehensive Comparison
| Serial Number | Item | Fixed Bed Dry Desulfurization | SDS Dry Desulfurization | Calcium-Based Desulfurizing Agent Direct Injection | Wet Desulfurization | Remarks |
| 1 | Temperature Requirements | Wide Applicability to Temperature, with requirements met at furnace gas temperatures as low as 100 degrees Celsius | Requires heating of the furnace original flue gas |
The furnace exhaust gas at temperatures above 100 degrees Celsius meets the requirements without the need for additional heating. |
No temperature requirements | The soda ash in SDS dry method needs to be heated to above 150 degrees Celsius for thermal decomposition, requiring a large amount of flue gas for heating |
| 2 | Maintenance Costs | Requires less frequent equipment maintenance, resulting in lower costs | Multiple equipment and facilities, extensive maintenance requirements, high costs | The same applies to SDS | Many equipment and facilities, extensive maintenance requirements, high costs | The fixed bed dry method is relatively simpler. |
| 3 | Operator Workforce | Equipment is maintenance-free, eliminating the need for dedicated operator positions | Many operating devices requiring manned positions. | The same applies to SDS | Many operating devices requiring manned positions; | Fixed bed dry desulfurization requires almost no maintenance. |
| 4 | Adjustability | Capacity can be adjusted through airflow distributors and spare towers for each desulfurization tower | Desulfurization capacity can be adjusted by varying the flow of sodium bicarbonate solution | The same applies to SDS | Desulfurization capacity can be adjusted by varying the amount of alkali salt input. | Both can be adjusted. |
| 5 | Maintenance | Few operational devices, minimal maintenance points | Equipment such as printers require regular spot checks, and equipment such as dust collectors require regular maintenance; | The same applies to SDS | Various pumps, nozzles, etc., require regular maintenance to prevent blockages and other issues; | SDSThe SDS dry desulfurization equipment involves more facilities, with a large workload for maintenance and repairs. |
| 6 | Equipment or Consumables Procurement | Main consumables are desulfurizing agents requiring regular replacement | Grinder equipment and reaction towers require regular maintenance, dust collectors, and bags that require regular cleaning or replacement | The same applies to SDS | Main consumables are alkali solutions such as sodium hydroxide or calcium hydroxide; | The performance of desulfurization and denitrification agents and the choice of suppliers are crucial. |
| 7 | Solid Waste Disposal | Calcium carbonate can be used as raw material in cement plants. | Sodium carbonate, relatively speaking, is more difficult to handle | Calcium carbonate, easier to handle. | Calcium carbonate can be used in the preparation of gypsum. | Handling SDS byproducts is challenging, and future disposal costs for sodium salts categorized as hazardous waste will be very high. |
Conclusion:
★ If considering small footprint, low investment, low operating costs, easy maintenance, and easy byproduct handling, the fixed bed dry desulfurization method should be chosen.
★ If SDS with a dust collector must be chosen, it is recommended to use calcium-based desulfurizing agents (replacing soda ash).
Using calcium-based desulfurizing agents (ultrafine powder) in direct injection form reduces grinder power consumption, produces calcium-based byproducts that are easy to handle, and can be recycled by our company.
★ If purely considering investment costs, wet desulfurization can be chosen.
This method can directly use metallurgical wastewater such as blast furnace slag water without increasing new freshwater consumption or sewage discharge.
Process Principle
This technology is the fixed bed dry desulfurization technology:
Desulfurizing agents catalytically oxidize sulfur dioxide in the flue gas to sulfur trioxide, which is then absorbed by calcium hydroxide to produce calcium sulfate:
SO2 + 1/2 O2 → SO3
SO3 + Ca(OH)2 → CaSO4 + H2O
Using a fixed bed-like technology, alkalis (such as lime, sodium carbonate, magnesium hydroxide, etc.) and catalyst-formed particles are loaded into the desulfurization reactor. After the flue gas passes through, sulfur dioxide is oxidized to sulfur trioxide and then reacts to solidify into calcium sulfate (gypsum).
Issues with SDS Dry Desulfurization, namely Soda Ash Dry Method
| Number | Issues | Solutions | Advantages of Calcium-Based Direct Injection Technology | |||
| 1 | The desulfurizing agent used is soda ash (sodium bicarbonate). With the increasing number of desulfurization projects, soda ash often faces supply shortages, leading to rising prices and increasing operating costs. | My company has introduced the calcium hydroxide ultrafine powder direct injection technology and the calcium-based desulfurization agent suitable for this technology through various methods such as laboratory experiments and practical engineering cases, which can replace the use of soda ash. | Resolved the problem of soda ash supply shortages and escalating costs, which significantly increased operational expenses. | |||
| 2 | When using soda ash, grinding equipment such as grinders is required to achieve a particle size of 700 mesh or even 900 mesh and above to meet effectiveness requirements. This results in higher initial investment, increased operating costs (electricity consumption), and additional maintenance and repair points. | Through laboratory experiments, engineering case studies, and other methods, our company has introduced the calcium hydroxide ultrafine powder direct injection technology, along with calcium-based desulfurizing agents suitable for this technology, which can replace soda ash. | Reduce initial investment (new projects no longer require grinding equipment and other facilities) and operating costs (no electricity consumption for grinders). |
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| 3 | The desulfurization product of this method is sodium sulfate. After sampling and testing multiple projects, the product composition is complex and difficult to handle. The classification of sodium sulfate (solid waste or hazardous waste) has not been clearly defined. | After adopting this calcium-based desulfurizing agent, there is no need for grinding equipment; the ultrafine powder can be directly conveyed using compressed air and similar methods. | Thus, it solves the problem of difficult-to-handle byproducts or high treatment costs. | |||
| 4 | When using soda ash for desulfurization, the flue gas reaction temperature generally ranges from 180 to 280°C, achieving high desulfurization efficiency. In industries such as steel, coking, and cement, where flue gas temperatures are lower, flue gas needs to be heated, increasing energy consumption. | .After using this calcium-based desulfurizing agent, the temperature range for flue gas desulfurization is broader (35~350ºC), which saves more energy compared to soda ash. | Addressing the issue of raising the inlet flue gas temperature for desulfurization, thereby reducing operating costs. |
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| 5 | When using soda ash for desulfurization, its desulfurization capacity is relatively weak, which is not conducive to integrated flue gas desulfurization, denitrification, and dust removal systems (where fluorine in the flue gas corrodes metal filter tubes, composite ceramics, etc.). |
Additionally, with this calcium-based desulfurizing agent, fluorine in the flue gas forms CaF2. The stability of CaF2 is higher than that of NaF, making calcium-based desulfurizing agents more effective in defluorination compared to sodium-based desulfurizing agents. |
Addressing the impact of fluorine in the flue gas on integrated desulfurization, denitrification, and dust removal systems. |
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| 6 | During soda ash desulfurization, the moisture content in the flue gas has minimal impact on the desulfurization efficiency. |
After using this calcium-based desulfurizing agent, the moisture content in the flue gas has a significant impact on desulfurization efficiency. Higher moisture content enhances the desulfurization effectiveness of the calcium-based desulfurizing agent, reducing corrosion in the ductwork equipment caused by moisture in the flue gas. | Addressing the impact of high moisture content in the flue gas on ductwork and equipment. | |||
★ Resolved the problem of continuously rising soda ash prices, thereby increasing operational costs for enterprises.
★ Addressed the issue of flue gas temperature affecting desulfurization efficiency.
★ Mitigated the impact of fluorine in the flue gas on integrated desulfurization, denitrification, and dust removal systems.
★ Higher moisture content in the flue gas (within a certain range) enhances desulfurization efficiency.
★ Reduced initial investment and operational costs during operation by decreasing electricity consumption.
★ Desulfurization byproducts are easy to handle, and our company can recycle them.
Specific (Modification) Plan and Pros and Cons Analysis
For existing projects:
Regarding the SDS dry desulfurization system with existing grinding and conveying systems:
Modification Plan 1:
Utilize the existing grinding and conveying systems; adjust the classifier frequency to 0 to avoid fine grinding, and then use a roots blower to transport calcium-based ultrafine powder.
Advantages:
Minimal modification required, maintaining the same feeding method.
Disadvantages:
Power consumption of the grinding equipment still exists.
Modification Plan 2:
If space permits, construct a new intermediate material warehouse and pneumatic conveying system to directly transport calcium-based ultrafine powder to the desulfurization tower.
Advantages:
Saves grinding equipment power.
Disadvantages:
Requires new equipment and facilities.
For new projects:
Constructing a new material warehouse with pneumatic conveying eliminates the need for grinding and other equipment, reducing initial investment.
Key Point 1: Solves the difficulty of handling sodium salt byproducts!
Key Point 2: Reduces operating costs by at least 30%.
Key Point 3: Fewer equipment and facilities simplify maintenance and upkeep.
Calculation of operating costs and economic analysis
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Economic feasibility Operating costs Savings |
2NaHC03(s)=Na2C03(s)+H20(g)+C02(g)--Soda ash decomposition S02(g)+Na2C03(s)=Na2S03(s)+C02(g)--Sodium-based reaction Ca(OH)2+S02=CaS03↓+H20--Calcium-based reaction From this, it can be seen that: 1 mole of sulfur dioxide requires 1 mole of calcium hydroxide and 2 moles of soda ash. Specifically, to absorb and treat 1 kilogram of sulfur dioxide, it requires approximately 1.156 kilograms of calcium hydroxide and 2.625 kilograms of soda ash. Considering a utilization rate of 90% for soda ash and a conservative estimate of 65% for calcium-based ultrafine powder, to absorb and treat 1 kilogram of sulfur dioxide requires approximately 1.78 kilograms of calcium hydroxide and 2.9 kilograms of soda ash. In conclusion: To absorb and treat the same amount of sulfur dioxide, the usage of calcium-based ultrafine powder is 60% of the usage of soda ash. |
Calculation provided for reference: Taking a gas consumption rate of 60,000 cubic meters per hour as an example for a heating furnace; After adopting calcium-based ultrafine powder direct injection technology, the operating costs are approximately 70% of those incurred using soda ash." |
Company Profile
Vision
With dees of rapid development and accumulation, China has been perfect and mature on technology and management in various industrial areas, shaping a complete processing manufacturing industry with competitive price, well known for its excellent skill, high efficiency and hardworking team with qualification for personnel dispatching.
| Professional Professional technical and management team with abundant experience in the implementation of domestic and international projects; |
| Responsive Responsively and meticulously, translating your needs into complete solutions; |
| Integration Integrating various technologies and resources in China and fulfilling complementary advantages, by relying on professional teams; |
| Motivation Motivated to provide the optimal solution and quality products; |
| Exceptional Exceptional, delivery and,implementation of projects to meet, your expectations; |
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