Hebei Cement Kiln Medium-temperature SCR DeNOx Project
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Project Case Studies
Temperature: 300°C–420°C
Inlet NOx concentration: 300 mg/Nm³
Emissions limits: NOx ≤ 50 mg/Nm³, PM ≤ 10 mg/Nm³
Description
I. Customer Needs and Pain Points
Core Customer Needs: Achieve ultra-low nitrogen oxide emissions from cement kiln flue gas, meet national environmental regulations for ultra-low emissions in the cement industry, and ensure continuous, compliant production.
Core Pain Points:
Cement kiln flue gas conditions are highly volatile, with elevated levels of dust and alkali metals. Traditional SCR systems are prone to catalyst alkali poisoning, clogging, and wear, resulting in significant fluctuations in denitrification efficiency. Additionally, these systems require large amounts of catalyst and have short replacement cycles.
Legacy denitrification systems feature complex layouts and occupy large amounts of space. Fan energy consumption is high, and frequent catalyst replacements drive up O&M costs, squeezing corporate production profits.
The original system struggles to maintain stable NOₓ outlet levels and cannot consistently meet the ultra-low emission standard of NOₓ ≤ 50 mg/Nm³.
II. Solution
Adopt Aiyipu’s proprietary medium-temperature SCR denitrification solution for cement kilns, designed for flue gas temperatures of 300–420°C. The system utilizes specialized 11-cell and 13-cell honeycomb denitrification catalysts:
Leveraging a CNAS-accredited laboratory, the catalyst formulation and process parameters were optimized. The catalyst exhibits excellent resistance to alkali poisoning and dust abrasion, making it perfectly suited for the high-dust, high-alkali, and medium-temperature operating conditions of cement kilns.
The solution integrates a fully modular design encompassing flue gas pretreatment and SCR denitrification, optimizing the layout of flue ducts and reactors. This eliminates the need for extensive new site space and simplifies the existing system piping.
The 11-hole and 13-hole catalyst specifications feature a reasonable specific surface area, smooth gas flow, and lower pressure drop, optimizing the total catalyst loading while ensuring denitrification activity.
III. Actual Compliance Results
After the project went into operation, flue gas parameters fully complied with the cement industry’s ultra-low emission standards:
Inlet NOₓ: 300 mg/Nm³; outlet NOₓ stably controlled at ≤50 mg/Nm³; denitrification efficiency ≥83%;
Particulate matter (PM) emissions stably maintained at ≤10 mg/Nm³; the system operates continuously and stably over the long term, completely eliminating the risk of NOₓ exceedances in flue gas. The company successfully passed online environmental monitoring and environmental acceptance inspections, completing its transition to green, low-carbon production.
IV. Operation and Maintenance Advantages
The entire denitrification system features a modular design with a streamlined structure and is equipped with a remote online monitoring system. Maintenance personnel can monitor equipment status in real time, requiring only 1–2 on-site inspections per month, eliminating the need for long-term on-site staff;
The 11/13-hole catalyst is manufactured from wear-resistant and alkali-resistant materials, making it suitable for the cement kiln’s year-round medium-temperature operating conditions of 300–420°C. The system achieves an operational availability rate of ≥99%, significantly reducing the frequency of malfunctions and ensuring uninterrupted, continuous production of the cement kiln.
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