Emission control innovations from the industry's largest R&D facility

What does FLSmidth offer?

With our 135+ years of experience in developing innovative technology, FLSmidth will help your plant comply with all environmental regulations – now, and in the future. From project development to after-sale services, we consistently deliver excellence in air pollution control.

 

FLSmidth® solutions include:

 

  • Particulate removal technologies, such as ESPs and fabric filters
  • SOx and HCl reduction technology
  • Catalytic technology for combined particle and gas removal
  • THC/VOC reduction technology
  • Heavy metal reduction technology, including mercury
  • Dioxin reduction technology
  • Low NOx technology.

 

As industry leaders, we are at the forefront of emission control research and development investment. We work hard to discover the most cost-effective solutions to help you meet local environmental regulations.

 

In our early years, our technology efforts were concentrated on the removal of dust particles. However, with our latest technological developments such as catalytic filter solutions, we are now able to remove not only dust, but also heavy metals, NH3, NOx, and a wide range of organic gaseous compounds. This means that our systems have become a driving force toward a cleaner future for many different applications including cement, steel, mining, pulp and paper, waste to energy and power.

 

Whether in our research and development department or in collaboration with universities and customers from around the world, we work tirelessly to develop new technologies and improve on existing ones. This allows us to respond in a more timely fashion to both customer requests and environmental legislation. To ensure a long lifetime for parts and components and to keep costs for replacement parts to a minimum, we also conduct extensive stress and wear testing of our equipment.

 

One source for APC support and spare parts

We are committed to supplying every spare part or service you require during the complete lifecycle of your air pollution control equipment.

 

We offer:

 

  • High-quality spare parts
  • Extensive support solutions covering your specific need
  • Specifically designed replacements for your equipment
  • Replacements for other OEMs’ APC equipment
  • Ability to convert and upgrade to ensure compliance with regulations

 

Process expertise

Our know-how can be one of your most valuable resources. It made the difference when a customer’s ESP installation was having problems complying with the emission permit. Our specialists discovered that the rapping system was not functioning well. We recommended a solution for modifying the existing system and for correcting the gas distribution, which brought the installation back into compliance.

 

Rapid response

A fast response to unexpected issues is just one way we help you achieve maximum uptime. For example – after overheating a portion of their filter bags one weekend, a cement manufacturer called our filter bag manufacturer, AFT, for help. Less than 24 hours after AFT was contacted, new filter bags were produced and air freighted overnight to the customer. By lunchtime the next day, the plant was up and running again.

 

Close relationships

We’ll support you throughout the lifetime of your equipment. One of our long-standing customer relationships began with the supply of an APC system, which was strengthened through regular service visits and yearly maintenance. For another customer, we helped with upgrades of both FLSmidth and non-FLSmidth equipment to ensure a continuing improvement in emission control capability. Upgrades like these can be planned in stages to match your investment plans. 

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Emission control solutions tailored to your needs

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Meeting emission guarantees

We are not satisfied until you are, which is why we give you performance guarantees based on a precise assessment of your plant and the experience we have collected from more than 8,000 APC systems installed.

For new equipment as well as existing equipment, we utilise the latest in computational fluid dynamics-based (CFD) predictive modelling software to estimate the actual levels that will be achieved once the plant is operating at full capacity. Our CFD simulation technology is very accurate thanks to our more than 15 years validating modelling with real field results.


For existing APC equipment, we measure emissions and make recommendations on how to improve our current solution.

Particulate matter

Our range of solutions for reducing dust emissions includes a broad selection of filters adapted to your specific needs.


Fabric filters

Fabric filters are available in either a standard design or a highly customised solution for your specific application. Both options offer the highest particulate removal efficiency possible, exceeding even the most stringent emissions requirement.


Electrostatic precipitator

Compact electrostatic precipitators (ESP) are designed with computational fluid dynamics (CFD) modelling to achieve maximum system removal efficiency. Conversion concepts of electrostatic precipitator to a fabric filter solution are available to ensure the most feasible solution.


Hybrid filter

Hybrid filter solutions, where both the ESP and fabric filter technologies are used, ensure optimum particulate removal efficiency. We also supply nuisance dust collectors for secondary dust removal, such as dust transport systems and silos.


Services

Additionally, we offer a wide range of services to help maintain, improve, and operate your air pollution control equipment with greater efficiency.


Performance standards for dust emissions continue to grow more stringent for all industries worldwide. This is why we offer a variety of options to help your company achieve your specific requirement for reducing particulate emissions.


We begin by analysing your existing equipment and processes to pinpoint problem areas, and then provide customised solution options to ensure that your plant remains in compliance with local emissions regulations.


To help maximise the operation of your air pollution control (APC) equipment, we will also provide a brief survey of your plant's equipment, which will focus on specific problem areas you may have. This is followed by a technical review summarising our observations and recommendations for your equipment.


A more in-depth evaluation of a specific process is also available through a system audit of your air pollution control equipment. This detailed analysis results in a written report outlining possible improvements for your plant’s air pollution control equipment and layout (from pick-up point to end-of-pipe), with a special focus on increasing equipment availability and efficiency while minimising energy consumption.

HCl

Our gas suspension absorber, the FLS® GSA, is a flexible multi-pollutant control system that provides more than 90% hydrogenchlorid (HCl) removal. Its small footprint makes it ideal for retrofit projects.

 

Our Hydrated Lime Injection (HLI) technology captures HCl and other pollutants by injecting hydrated lime into the flue gas in the duct leading to the dust filter.

 

Services

A base-line emissions audit of your plant performed by FLSmidth includes:

 

  • on-site stack testing
  • process analysis
  • raw material sampling

 

These results are analysed by process specialists who provide a report which compares current emissions levels against current or future limits, identifies the sources of any emission problems, and recommends practical and economical solutions for improvement.

Hg

Particulate mercury can be collected in fabric filters or ESPs.


Our gas suspension absorber, the FLS® GSA, is a flexible multi-pollutant control system that provides up to 90% mercury removal. Its small footprint makes it ideal for retrofit projects.


We also provide a full line of Activated Carbon Injection equipment and Particulate Control Devices for mercury abatement. For medium level mercury reduction of up to 70%, we offer the patented Mercury Roaster System.


Services

A base-line emissions audit of your plant performed by FLSmidth includes on-site stack testing, process analysis, and raw material sampling.


These results are analysed by process specialists who provide a report that compares current emissions levels against current or future limits, identifies the sources of any emission problems, and recommends practical and economical solutions for improvement.


We also provide Environmental Impact Assessments for European greenfield projects.

NOx

Worldwide emissions of nitrogen oxides (NOx) cause a wide range of health and environmental effects, such as smog and the reduction of air quality in urban areas. Because of these negative effects, the World Bank and many countries are imposing increasingly tougher environmental restrictions on NOx emission.

 

Most new kiln systems, however, are pushed to their limits, with strong, hot burning zones that result in high thermal NOx generation. NOx is also released from oxidation of nitrogen

 

compounds in the calciner's fuel. Therefore, it is essential for cement and minerals producers to ensure that the kiln process is not compromised and that they remain in compliance with emission regulations.

 

Our preheater installations for new cement plants include the proven Low-NOx Calciner, which provides for high levels of NOx reduction from both thermal and fuel NOx. For situations in which primary abatement techniques aren’t enough, we also offer secondary abatement techniques, such as Selective Non-Catalytic Reduction (SNCR).

 

If your plant requires NOx, NH3, and VOC emission control combined with dust emission control, our CataFlex catalytic filter bags provide single step SCR technology for a more efficient solution.

 

Services

A base-line emissions audit of your plant performed by FLSmidth includes:

 

  • on-site stack testing
  • process analysis
  • raw material sampling

 

These results are analysed by process specialists who provide a report which compares current emissions levels against current or future limits, identifies the sources of any emission problems, and recommends practical and economical solutions for improvement.

SO2

We offer several systems for reducing sulphur dioxide (SO2) emissions depending on the reduction level:

 

Our D-SOx Cyclone system is a means of achieving SO2 emissions reduction in the range of 25-30% by taking advantage of the free lime that is created in the calciner.

 

Our Hydrated Lime Injection (HLI) system can reduce SO2 emission by up to 60% by injecting hydrated lime powder either pneumatically into the preheater or bypass system or via a mechanical feed into the preheater kiln feed.

 

Additionally, our gas suspension absorber, the FLS® GSA, is a multi-pollutant control system that provides a high level of SO2 removal of up to 97%, depending on outlet temperature.

 

For higher removal, we also provide third-party wet scrubber technology.

 

Services

The World Bank and many countries are imposing increasingly tougher environmental restrictions on SO2 emission.

 

In cement plants, SO2 emissions are generated from sulphur compounds in the raw materials and, to a lesser extent, from sulphur in the fuel. It is therefore essential for

 

cement producers to ensure that the kiln process is not compromised and that they remain in compliance with local emission regulations.

 

A base-line emissions audit of your plant performed by FLSmidth includes:

 

  • on-site stack testing
  • process analysis
  • raw material sampling

 

These results are analysed by process specialists who provide a report which compares current emissions levels against current or future limits, identifies the sources of any emission problems, and recommends practical and economical solutions for improvement.

TOC

The CataMax™ catalytic filter is a single step solution for the cement industry to reduce Total Hydrocarbons (THC) emissions including Hazardous Air Pollutants (HAPs). This solution combines our extensive process know-how and the latest technologies within air pollution control for cement plants.

 

Particulate emission from the gas stream is captured on the surface of the filter’s porous ceramic elements. A specially designed catalyst then converts and removes THC and NOx emissions originating from the raw materials and the combustion process. The initial removal of dust prevents it from deactivating the embedded catalyst. The conversion process of the harmful gases requires elevated temperatures as present in the down comer from a preheater/calciner kiln.

 

Services

A base-line emissions audit of your plant performed by FLSmidth includes:

 

  • on-site stack testing
  • process analysis
  • raw material sampling

 

These results are analysed by process specialists who provide a report which compares current emissions levels against current or future limits, identifies the sources of any emission problems, and recommends practical and economical solutions for improvement.

 

FLSmidth also provides Environmental Impact Assessments for European Greenfield projects.

Industries served

Our extensive process knowledge enables us to design the right configuration to your industry-specific application.

 

We have installed APC systems in many industries, including:

 

  • Cement
  • Lime
  • Pulp & Paper
  • Iron & Steel
  • Copper
  • Alumina and bauxite
  • Nickel

 


Smart filter technology

The combination of optimised design, improved mechanical construction, and advanced filter control results in reduced and easier maintenance, compared to other types of fabric filters on the market. The SmartBag coupled with the SmartPulse Controller EVO II meets the needs of modern-day cement mills.

Smart fabric filter technology

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Reducing SO2 emission more than 97%

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Reducing emissions far below target

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Air pollution control services

Dealing with emissions responsibly and efficiently is a fact of life for today’s production facilities. Maintaining air pollution control equipment is critical for your production, profitability and the environment. In today’s world of strict emissions control, it’s a necessity.

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