Hebei Cement Kiln Medium-Temperature DeNOx Project
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Project Case Studies
Description
I. Customer Needs and Pain Points
The customer’s core need is to achieve integrated ultra-low emissions for dust and nitrogen oxides in cement kiln flue gas, meet national and local environmental protection requirements for ultra-low emissions, and ensure compliant and stable production. Key Challenges:
Cement kiln flue gas is characterized by high temperatures (260–420°C), high dust concentrations, and significant operational fluctuations. In traditional processes that treat NOx before dust removal, catalysts are prone to clogging, wear, and poisoning, resulting in unstable NOx removal efficiency, high catalyst consumption, and frequent replacements.
It is difficult to achieve simultaneous compliance for both dust and nitrogen oxides. Traditional systems are complex, require large footprints, consume high amounts of energy during operation, and incur persistently high O&M costs, severely impacting corporate production efficiency.
II. Solution
Adopting Aiyipu’s proprietary integrated high-temperature dust removal and denitrification solution for cement kiln flue gas—which revolutionizes traditional process routes—employs a “high-temperature metal baghouse dust removal + medium-temperature SCR denitrification” integrated treatment process:
Leveraging a CNAS-certified laboratory to precisely optimize process parameters, the solution integrates modules for pretreatment, high-temperature dust removal, and medium-temperature denitrification, enabling coordinated control of multiple pollutants. It requires no additional space and is tailored to the high-temperature, high-dust, and high-sulfur-nitrate operating conditions of cement kilns.
Combining high-temperature-resistant metal filter bags with high-efficiency, wide-temperature-range denitrification catalysts, the system performs dust removal before denitrification. This significantly reduces dust-induced wear and catalyst poisoning, extends catalyst lifespan, and reduces replacement frequency.
III. Post-Implementation Standards and Results
Following project implementation, flue gas emissions fully meet the cement industry’s ultra-low emission standards:
Nitrogen oxide (NOₓ) emission concentration is stably controlled at ≤50 mg/Nm³
Particulate matter (PM) emission concentration is stably controlled at ≤10 mg/Nm³
The system operates stably, with flue gas emissions consistently meeting standards over the long term. It fully complies with the cement industry’s air pollutant emission standards, completely resolves the issue of excessive emissions from cement kiln exhaust, and helps enterprises successfully pass environmental acceptance inspections to achieve a transition to green production.
IV. Optimization of Operating Costs
Compared to traditional treatment processes, operating costs are significantly reduced:
Catalyst consumption is reduced by over 60%, substantially lowering procurement and replacement costs
Induced draft fan energy consumption is reduced by approximately 25%, leading to a significant decrease in overall system energy consumption
Comprehensive operating costs (including chemicals, energy consumption, and equipment wear and tear) are reduced by 20%–30%, saving the enterprise hundreds of thousands of yuan in annual operating expenses and significantly enhancing economic benefits.
V. Post-Installation Maintenance and Operational Advantages
The system features a modular design with a simple structure. Post-installation maintenance does not require a dedicated on-site team. Equipment operating status can be monitored in real-time via remote monitoring, and maintenance needs can be met through periodic inspections, with maintenance required only 1–2 times per month.
The equipment is constructed from high-temperature-resistant and wear-resistant materials, making it suitable for the long-term high-temperature and high-dust operating conditions of cement kilns. The system achieves an availability rate of over 99%, with no frequent breakdowns, significantly reducing maintenance labor requirements and ensuring the production continuity of the cement clinker production line remains unaffected.
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