Low-Temperature CO-SCR DeNOx Project for Lime Kilns in the Soda Ash Industry
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Description
I. Customer Needs and Pain Points
The customer’s core need is to achieve efficient denitrification and simultaneous purification of carbon monoxide in lime kiln flue gas within the soda ash industry, thereby meeting national and local ultra-low emission environmental standards and ensuring compliant and stable production.
Key Challenges:
Lime kiln flue gas is characterized by low temperature (180–220°C), significant operating fluctuations, and high dust content. Traditional SCR catalysts lack sufficient activity, making it difficult to achieve stable and compliant denitrification efficiency.
Conventional processes focus solely on denitrification and cannot simultaneously treat CO in the flue gas, creating pressure for secondary treatment. Additionally, these systems are complex and require a large footprint.
Under low-temperature conditions, catalysts are prone to poisoning and wear, resulting in high consumption, frequent replacements, and high O&M costs, which severely impact the company’s production efficiency.
II. Solution
Adopt Aiyipu’s proprietary integrated low-temperature CO-SCR denitrification solution for lime kilns, which employs “low-temperature SCR denitrification + CO co-purification” as its core process, tailored for low-temperature flue gas conditions of 180–220°C:
Equipped with a CO-SCR catalyst specifically optimized for low-temperature environments, this solution ensures a denitrification efficiency of ≥90% while achieving high-efficiency CO conversion, thereby simultaneously resolving the challenge of synergistic treatment of nitrogen oxides and carbon monoxide.
Relying on a CNAS-accredited laboratory to optimize process parameters, the solution adopts a modular design that integrates the entire process—from pretreatment to denitrification and CO purification—without requiring additional space. It is specifically tailored to the lime kiln’s high-temperature, high-dust, and highly variable operating conditions.
The catalyst formulation offers excellent resistance to poisoning and wear, significantly extending service life and reducing replacement frequency.
III. Post-Implementation Results and Standards
Following project implementation, flue gas emissions fully meet the ultra-low emission standards for the soda ash industry:
Nitrogen oxide (NOₓ) emission concentrations are consistently maintained below 50 mg/Nm³, with a denitrification efficiency of ≥90%
Carbon monoxide (CO) purification efficiency is ≥99%, simultaneously ensuring CO emissions meet regulatory standards
The system operates stably, with flue gas emissions consistently meeting standards over the long term. It fully satisfies the ultra-low emission requirements of the soda ash industry, helping enterprises successfully pass environmental inspections and achieve a transition to green production.
IV. Optimization of Operating Costs
Compared to traditional denitrification processes, the project’s comprehensive operating costs have been significantly reduced:
The consumption of low-temperature, high-efficiency catalysts has been reduced by more than 60%, substantially lowering procurement and replacement costs
Energy consumption of induced draft fans has been reduced by approximately 20%, resulting in a significant decrease in overall system energy consumption
Total operating costs (including chemical reductants, energy consumption, and equipment depreciation) 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 status can be monitored in real-time via remote monitoring, and maintenance needs are met with just 1–2 routine inspections per month.
The catalyst and equipment are constructed from high-temperature-resistant and wear-resistant materials, making them suitable for the lime kiln’s long-term low-temperature, high-dust operating conditions. The system achieves an availability rate of over 99%, with no frequent failures, significantly reducing maintenance labor requirements and ensuring that lime kiln production continuity remains unaffected.
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