Medium-Temperature DeNOx Project for Exhaust Gas from a 12×1000 kW Electric Arc Furnace in Inner Mongolia
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Project Case Studies
Description
1. Customer Needs and Pain Points:
The customer’s core need is to achieve ultra-low NOₓ emissions from gas internal combustion engine exhaust, meet environmental requirements in applications such as distributed energy, airports, and industrial parks, and ensure stable operation of the units. The core challenges include high exhaust gas temperatures (500–550°C), significant load fluctuations, and limited installation space. Traditional DeNOx systems are bulky and lack adaptability, making them unsuitable for on-site installation conditions; low DeNOx efficiency, leading to frequent NOₓ exceedances; catalysts deactivate easily at high temperatures, requiring frequent replacement and resulting in high O&M costs; and high system backpressure, which affects the operational efficiency of the gas internal combustion engine.
2. What solution was implemented:
The AIREP Ultra-Low Emission Solution for Gas Engine Exhaust was adopted, featuring a compact SCR DeNOx system paired with specialized high-temperature-resistant and anti-caking catalysts. The reactor structure was optimized, and a miniaturized, modular design was employed to accommodate the space constraints typical of gas engine installation sites; Leveraging the company’s core technologies, the system is equipped with a PLC-based intelligent control system that dynamically adjusts ammonia injection rates and operating parameters to achieve load adaptability, effectively addressing the wide load fluctuations typical of gas internal combustion engines.
3. Standards and Results Achieved After Implementation:
Following implementation, the system meets the ultra-low emission requirements of the “Emission Limits and Measurement Methods for Exhaust Pollutants from Internal Combustion Engines for Non-Road Mobile Machinery” (GB 20891-2014). NOₓ emission concentrations are consistently maintained below 75 mg/Nm³ (at 5% oxygen content), with some projects achieving levels below 50 mg/Nm³. DeNOx efficiency exceeds 90%, ammonia slip ≤ 3 mg/Nm³, and system backpressure is maintained within a reasonable range without affecting the operational efficiency of the gas-fired internal combustion engine, fully meeting environmental compliance requirements for applications such as distributed energy and airports.
4. Reduction in Operating Costs:
The compact design reduces equipment investment, extends catalyst lifespan by 2.5 times, lowers catalyst replacement costs by 60%, and reduces system energy consumption by 20%. Overall operating costs are reduced by 25%–30%, saving enterprises tens of thousands of yuan annually in O&M and equipment replacement expenses, effectively controlling the environmental operating costs of gas internal combustion engines.
5. Advantages such as convenient maintenance and stable operation:
The system features a compact, modular design with a small footprint, making it suitable for sites with limited space and easy to install; Equipped with an intelligent remote monitoring system, it enables real-time monitoring of operating parameters and automatic fault alerts. Maintenance features an online replacement design that requires no shutdown, with maintenance required only once every two months, reducing labor costs by 50%. The catalyst exhibits strong resistance to high temperatures and ash buildup, ensuring stable system operation with an availability rate exceeding 99.8%. It is well-suited for gas internal combustion engines operating under conditions of significant load fluctuations and frequent start-stop cycles, ensuring continuous and stable operation of the units.
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