Introduction
Flue gas cleaning is a critical environmental and industrial process that reduces the pollutants released from burning fossil fuels such as natural gas, wood, oil, and coal. This process helps maintain local and regional air quality and plays a significant role in meeting national-level clean air standards by controlling the amount of emitted pollutants. The importance of flue gas cleaning systems extends beyond environmental compliance; it also ensures a healthier and more productive work environment, highlighting its significance in industrial operations.In this guide, you will learn about the various flue gas cleaning methods and technologies and the associated challenges of flue gas cleaning technology. Whether you are involved in environmental management or industrial operations or are simply interested in understanding the impact of these processes on our environment, this guide will provide comprehensive thoughts into the world of flue gas cleaning.
Flue Gas Cleaning trends, emergent technologies, what is worth investing in our days, and beyond
Technological progress in the development of metallurgical processes goes hand in hand with the responsibility of big business to society, including environmental protection and handling of mineral resources.
The civilized world closely monitors global warming processes and greenhouse gas emissions from human activity, especially in producing steel and alloys. The contribution of the metallurgical industry to the volume of global carbon monoxide emissions is up to 9% of the total volume produced by humanity. In 2019, the European Commission adopted a plan to achieve zero greenhouse gas emissions in member countries of the European Union, according to which it is planned to reduce greenhouse gas emissions by 50% compared to 1991 levels and achieve climate neutrality by 2050.
The most current trends in reducing carbon oxide emissions are the transition to electrometallurgical processes and the simultaneous development of green energy, which will cover the needs of electrometallurgical production.
All investments into flue gas cleaning aim to reduce anthropogenic impact on the environment, reduce the carbon footprint of products, and recycle captured dust.
Why is Flue Gas Cleaning Important?
During the production of metallurgical alloys, flue gases are cleaned of suspended particles not identified by composition and of gaseous contaminants such as SO2, NOx, CO, etc.
It is essential to understand that due to the large volume of flue gases generated by technological units, the pollutants in these gases are measured in tons. Without purification facilities, all contaminants will get into the atmosphere and the human body with inhaled air or food products grown near steelmaking enterprises, water, and many other ways.
In the context of modern ethics and business rules, business owners invest vast amounts of money in modernizing gas-cleaning equipment to decrease the anthropogenic impact on the atmosphere.
Industries that Need Flue Gas Cleaning
Any production that involves the following factors needs a flue gas cleaning system:
- mechanical processing of a workpiece, material, or ore, including transportation, handling, separation, and screening during the preparation of materials for use;
- melting processes, followed by the pouring of metal supernatant liquids;
- preparation of iron and steel laddles, breaking of lining, etc.
Flue Gas Cleaning Techniques to Improve Flue Gas Treatment Efficiency
The selection of flue gas purification methods depends on specific parameters, the composition of gases, and the degree of purification required to comply with environmental safety standards. Combining several methods can also improve cleaning efficiency.
Basic methods of flue gas cleaning
1. Electrostatic precipitators
Electrostatic precipitators are used to remove solid matter and aerosols from flue gases. They create an electric field that attracts particles and traps them on charged surfaces.
2. Wet-type gas cleaning plants
These installations use water or other liquids for absorbing and removing gases, such as sulfur dioxide and ammonia. Wet-type gas cleaners are often used in energy and industrial sectors to remove harmful components from flue gases.
3. Bag filters. Particulate filters
Fabric or ceramic filters are used to capture solid matter in flue gases. They can be used for preliminary cleaning before other methods of chemical neutralization of gaseous pollutants.
4. Sorption filter
These filters absorb certain gases, such as hydrogen sulfide and carbon dioxide. They contain sorbents that chemically bind harmful gases.
5. Catalyzers
Catalyzers convert harmful gases into less harmful products through chemical reactions. For example, catalyzers can convert nitrogen oxides (NOx) into nitrogen and water.
6. Heat treatment:
Heat treatment, such as combustion or pyrolysis, destroys organic pollutants in flue gases.
Currently, fabric filters are widely used for cleaning flue gases. They are mainly bag filters. Electric precipitators are also used, proven efficient in purifying high-temperature gases and collecting dust with high electrical resistivity.
Check out our industrial dust collection system design and engineering services.
When developing a technical solution for flue gas capture and cleaning, our main task is to balance material costs and the resulting effect.
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M HEAVY TECHNOLOGY Experience and Expertise in Flue Gas Cleaning
| No | Enterprise name | Facility Name | Time of works | System performance | Special features of the flue gas cleaning systems and equipment |
| 1 | Northern Iron Ore Beneficiation Works (SEVGOK), Kryvyi Rih | Reconstruction of Lurgi-552-B burning kiln. Pellet production shop No 2. | 2017 | 226 800 m3/h | Three-field electrostatic precipitator Guarantee dust concentration at the stack exit – 50 mg/nm³ |
| 2 | Azovstal Iron and Steel Works, Mariupol | Capital overhaul of BF No 6 cast house and stock house dedusting systems. | 2017 | Cast house GCP – L=700 000 m3/h Stockhouse GCP – L=500 000 m3/h | Cast house GCP Modernization of the existing tree-field ESP. Guarantee dust concentration at the stack exit – 50 mg/nm³ Stock house GCPFiltration surface of the filter – 6600 m². Guarantee dust concentration at the stack exit – 20 mg/nm³ |
| 3 | Dnieper Metallurgical Combine,Kamianske | Sinter shop No 2. Modernization of the process gas purification system and air supply to the sinter cooling area of sinter machines No’s 7-12. | 2018 | 450 000 m3/h | Modernization of existing battery cyclones. Guarantee dust concentration at the stack exit – 125 mg/nm³ |
| 4 | Dnieper Metallurgical Combine,Kamianske | Sinter machine No 7 overhaul with modernization of the air supply system to the sinter cooling area and installation of the sinter machine shelter. | 2019 | 450 000 m3/h | Modernization of existing battery cyclones. Guarantee dust concentration at the stack exit – 125 mg/nm³ |
| 5 | Azovstal Iron and Steel Works, Mariupol | BF No 2 overhaul. Dedusting plants of BF No 2 cast house and stock house. | 2019 | Cast house GCP – L=1100 000 m3/h Stockhouse GCP – L=600 000 m3/h GCP Receiving hopper – L=540 000 m3/h | Cast house GCPFiltration surface of the filter – 10 800 m² Guarantee dust concentration at the stack exit – 20 mg/nm³ Stockhouse GCPFiltration surface of the filter – 7200 m² Guarantee dust concentration at the stack exit – 20 mg/nm³ GCP Receiving hopper Filtration surface of the filter – 7200 m² Guarantee dust concentration at the stack exit – 20 mg/nm³ |
| 6 | ArcelorMittal Kryvyi Rih, Kryvyi Rih | Modernization of BF No 9. Dedusting systems of BF No 9 cast house and stock house. | 2021 | Cast house 1 GCP – L=1200 000 m3/h Cast house 2 GCP – L=1200 000 m3/h Stockhouse GCP – L=1350 000 m3/h | Cast house GCP – 2 installations Filtration surface of the filter – 25800 m² Guarantee dust concentration at the stack exit – 20 mg/nm³ Stockhouse GCP Filtration surface of the filter – 28800 m² Guaranteed dust concentration at the stack exit – 20 mg/nm³ |
| 7 | Azovstal Iron and Steel Works, Mariupol | Reconstruction of converter gas cleaning system, BOF shop. | 2021 | Point-source emissions L=500 000 m3/h, fugitive emissions L=1150 000 m3/h | Point-source emissions – ESP Guarantee dust concentration at the stack exit – 50 mg/nm³ Fugitive emissions – Bag filter Guarantee dust concentration at the stack exit – 20 mg/nm³ |
| 8 | Illich Steel and Iron Works, Mariupol | Construction of a system for capture and cleaning fugitive convertor emissions | 2022 | 1 420 000 m3/h | Filtration surface of the filter – 14 440 m² Guarantee dust concentration at the stack exit – 20 mg/nm³ |
A distinctive feature of our experts is their practical experience in supporting and implementing design solutions. M HEAVY TECHNOLOGY engineers specialize in the design of flue gas cleaning plants and know technological processes of steelmaking, coke, blast furnace design, and other processes, for which they successfully carry out their projects.
Author of the article: Dmytro Semenov
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