How to Improve Air Pollution–Control with CFD- Modeling

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Siemens Industry Software GmbH Digital Factory Division

CFD analyses enabled engineers to proactively decide on what approaches to take during each step of the design phase. There are many factors that contribute to achieving an optimal design. For example, knowing the continuum concentration distribution of NO_x and NH₃, the temperature profiles, and the velocity patterns within the system are critical. If the profiles are highly skewed, engineers could perform CFD analysis on the number of required mixers to achieve a homogenous distribution. If the profiles are relatively well distributed, a tunable AIG may suffice without the need for a mixer which increases pressure loss.

Furthermore, the GSG provides the optimally distributed uniform gas velocities into the catalyst where space is limited. With all of these upstream NO_x removal technologies and flow distribution devices including AIG, static mixer, and Fuel Tech’s patented GSG technology, the SCR system can be fully optimized. Each of these NO_x reduction components is optimized by the extensive use of advanced Computational Fluid Dynamics which enables engineers to take a system-wide design approach resulting in considerable cost savings compared to going to ground with a traditional stand-alone SCR facility and trouble-shooting problem areas later as they arise.

I-NO_x has been estimated to achieve de-NO_x rates of up to 85% at less than half the capital costs of stand-alone SCR. Installed costs are estimated to be in the range of $100-150 per kW for an I-NO_x installation compared to $300 per kW for a full stand-alone SCR. In a coal-fired power plant in Hong Kong, many elements of I-NO_xhave been successfully implemented and helped the unit exceed all performance criteria. Because of the successful achievement at this facility, Fuel Tech continues to receive more orders for complete I-NO_x retrofits (combustion modification, SCR, and SNCR) from other facilities throughout the world.

Conclusion: The rapid development of computer hardware and CFD technology has brought engineers a revolutionary tool in addressing all the complexities needed for APC at power plants and industrial facilities.

The result is a high performance pollution control system capable of meeting strict environmental regulations while maintaining the low capital and operating costs.

* * The author ist General Manager at Fuel Tech, Inc.

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