SO₂-, HCl- und Säuregasabscheidung

Name: SO₂-, HCl- und Säuregasabscheidung
Brand: MDSJ Process | DUCON

SO₂-, HCl- und Säuregasabscheidung durch Trockensorption: DUCON Injektionssysteme mit Kalkhydrat, Natriumbicarbonat und Aktivkohle zur Rauchgasreinigung.

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SO₂-, HCl- und Säuregasabscheidung

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SO₂-, HCl- und Säuregasabscheidung

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Abscheidung von SO₂, HCl und Säuregasen

Bei der Reinigung von Luft-/Gasemissionen aus industriellen Abluftströmen, Krankenhausabfällen und Abfallverbrennungsanlagen (Waste to Energy - swi) verfügt DUCON über langjährige Erfahrung in der Bereitstellung von Lösungen, die den lokalen Umweltvorschriften und -auflagen entsprechen. Hierbei erfordert die Rauchgasreinigung die Injektion von Pulvern wie Calciumhydroxid (Kalk), Natriumbicarbonat, Soda und PAC-Aktivkohle, um die Schadstoffe im Rauchgas abzuscheiden. Jeder Schadstoff hat sein spezifisches Pulver und sein DUCON Sorbenssystem. Dank des speziell konstruierten Komplettsystems von DUCON werden die Säuregaspartikel durch das in den Kanal injizierte Trockenreagenz erfasst. Anschließend werden diese Partikel am Ende des Prozesses im Schlauchfilter abgeschieden.

Die Trockensorbens-Auslegung bietet ein maßgeschneidertes und komplettes System zur Injektion von Pulver in die Verbrennungskanäle. In der Regel umfasst der Lieferumfang folgende innovative Komponenten:

Zylindrisch-konisches Lagersilo, mechanisches oder druckluftbetriebenes Austragssystem, Dosierschneckenförderer mit Brückenbrecher/rotierendem Siloaktivator. Zur Versorgung getrennter/mehrerer Injektionspunkte können wir bis zu 4 unabhängige Dosierer integrieren.
Komplettes pneumatisches Fördersystem, speziell ausgelegt für jedes Trockenreagenz, vom Zentrifugal- oder pneumatischen Gebläse bis zum Injektionspunkt.

Mechanischer Siloaktivator (DUCON Siloaktivator)

Dieses System ist mit einem flexiblen Schneckenförderer kombiniert. Unabhängig von der Silokapazität garantiert die Siloaustragseinheit die Durchflusskontrolle und die präzise Dosierung pulverförmiger Produkte wie Kalkstein, Löschkalk, pulverförmiger Aktivkohle und Natriumbicarbonat.

Mechanischer Behälteraktivator (DUCON Siloaktivator):

Um die Genauigkeit des volumetrischen Dosierers zu erhöhen, kann die Ausrüstung mit einer elektronischen Einrichtung ausgestattet werden, die den Gewichtsverlust erfasst und ihn so in einen gravimetrischen Dosierer verwandelt. Der Brückenbrecher bzw. die Siloaustragsvorrichtung ist mit einem Flachschieber ausgestattet und arbeitet vollständig mechanisch. Das Produkt wird stets im Dosierer gehalten, was unabhängig von der Beladung des Silos eine präzise Dosiergenauigkeit garantiert. Der mechanische Siloaktivator kann an neuen oder bestehenden Silos installiert werden. Der Förderer übernimmt den Transport des Produkts zur Prozessanwendung. An einem Silo können mehrere flexible oder starre Schneckendosierer installiert werden.

Durch die Installation eines MDS 800 Brückenbrechers unter dem Silo können bis zu 4 Schneckendosierer mit unterschiedlichen Ausläufen installiert werden. Dies ist eine effiziente Lösung für Gasreinigungssysteme, bei denen mehrere Verbrennungslinien versorgt werden müssen.

What Is Acid Gas Removal and Which Pollutants Does It Target?

Acid gas removal is a flue-gas treatment process that neutralizes the acidic components of combustion and process flue gas — mainly sulfur dioxide (SO2), hydrogen chloride (HCl), and hydrogen fluoride (HF) — with an alkaline sorbent to bring emissions below regulatory limits.
It differs from dust-only jet-pulse filtration: the goal here is not merely to capture particulate but to convert gas-phase acidic molecules into solid salts by chemical reaction.
There are three main routes: dry sorbent injection (DSI), semi-dry (spray dryer absorber / SDA), and wet scrubbing (wet FGD). The choice depends on acid load, target efficiency, water/wastewater constraints, and capital budget.
Secondary pollutants (SO3, dioxins/furans, heavy metals, mercury) can be co-controlled by adding activated carbon to the same sorbent line.
In DUCON solutions, acid gas removal is typically integrated with a downstream bag filter — the sorbent reacts in the gas duct, and the resulting solid reaction products are captured on the filter media.

Routes: Dry, Semi-Dry, and Wet System Comparison

Dry Sorbent Injection (DSI) — a powdered sorbent (hydrated lime Ca(OH)2 or sodium bicarbonate NaHCO3) is injected directly into the gas duct. Lowest capital cost, most compact, no water; SO2 efficiency is typically 50-70% with lime and up to ~90% with activated sodium bicarbonate.
Semi-Dry (SDA / spray absorber) — a lime slurry (Ca(OH)2 milk) is sprayed into the reactor; SO2 is absorbed as the water evaporates. SO2 efficiency is typically 85-95%; more sorbent-efficient than DSI but requires a slurry preparation unit.
Wet Scrubbing (Wet FGD) — SO2 is absorbed in a scrubbing tower with a lime/limestone slurry; efficiency is 95-99%+ and gypsum (CaSO4·2H2O) can be recovered as a by-product. Highest efficiency, but wastewater/slurry handling and the highest capital cost.
The temperature window sets the route: lime-based DSI typically 140-180°C, activated sodium bicarbonate above ~140°C, SDA 15-20°C above the water dew point (~140-160°C).
Rule of thumb: DSI for low-to-moderate acid load and variable emissions; SDA for moderate-to-high SO2 load; wet FGD for very high SO2 load and gypsum recovery.

Reaction Chemistry, Sorbent, and Stoichiometry

With hydrated lime: Ca(OH)2 + SO2 → CaSO3·½H2O (calcium sulfite), which oxidizes to CaSO4·2H2O (gypsum) with oxygen. Ca(OH)2 + 2 HCl → CaCl2 + 2 H2O; Ca(OH)2 + 2 HF → CaF2 + 2 H2O.
With sodium bicarbonate: 2 NaHCO3 + SO2 (+½O2) → Na2SO4 + 2 CO2 + H2O; NaHCO3 + HCl → NaCl + H2O + CO2. Thermally decomposing bicarbonate forms a porous, high-surface-area soda that is highly reactive.
The stoichiometric ratio (NSR — normalized sorbent ratio) varies by route: dry lime DSI typically 2.0-3.0; activated sodium bicarbonate 1.1-1.5; semi-dry 1.3-1.6; wet FGD around 1.0-1.05. Lower NSR means lower reagent cost and less solid residue.
HCl and HF react faster and at lower stoichiometry than SO2; consequently, in the same system, HCl/HF efficiency is generally higher than SO2 efficiency.
Sorbent particle size is critical: with in-line milling to increase surface area, the same efficiency is reached at a lower NSR — cutting reagent consumption and operating cost.

Industries Served and System Integration

Waste incineration (municipal/hazardous) — HCl, HF, SO2, and dioxin/mercury control; typically a sorbent + activated carbon + bag filter combination.
Cement and lime industry — kiln and clinker SO2/HCl removal; fast dosing response to emission swings from variable raw materials.
Thermal power and biomass boilers — SO2 abatement from coal/biomass; semi-dry or wet route at high load.
Glass, ceramics, and metallurgy — HF/SO2/HCl treatment in furnace stack gas.
The system can be integrated upstream of an existing bag filter; filtration area and pressure-drop margin are re-evaluated for the new sorbent load.
DUCON delivery is end-to-end: sorbent silo, dosing/injection unit, reaction duct, downstream bag-filter integration, controls, and commissioning.

Frequently Asked Questions

What is acid gas removal (SO2, HCl, HF)?

It is a flue-gas treatment process that neutralizes acid gases — SO2, HCl, and HF — with an alkaline sorbent (hydrated lime Ca(OH)2 or sodium bicarbonate), converting them into solid salts and bringing emissions below regulatory limits. The resulting solid reaction products are captured in a downstream bag filter.

What is the difference between dry, semi-dry, and wet systems?

Dry (DSI) injects a powdered sorbent into the gas duct, uses no water, and has the lowest capital cost; SO2 efficiency is typically 50-90%. Semi-dry (SDA) sprays a lime slurry, with 85-95% SO2 efficiency. Wet (Wet FGD) uses a slurry in a scrubbing tower, reaching 95-99%+ with recoverable gypsum but generating wastewater. The choice depends on acid load, target efficiency, and budget.

Which sorbent should be used — lime or sodium bicarbonate?

Hydrated lime Ca(OH)2 is typically economical for HCl/HF-driven emissions and low-to-moderate SO2. When high SO2 efficiency is needed (~90% on the dry route), sodium bicarbonate (NaHCO3) is preferred; it thermally decomposes into a high-surface-area reagent and works at lower stoichiometry. The final choice follows the gas analysis and reagent price.

What products form after the reaction?

With lime, SO2 → calcium sulfite (CaSO3·½H2O), which oxidizes to gypsum (CaSO4·2H2O); HCl → CaCl2, HF → CaF2. With sodium bicarbonate, SO2 → Na2SO4 and HCl → NaCl. These solids are captured as dust in the bag filter and removed from the system for disposal or recovery.

What should the stoichiometric ratio (NSR) be?

It varies by route: dry lime DSI is typically 2.0-3.0, activated sodium bicarbonate 1.1-1.5, semi-dry 1.3-1.6, and wet FGD around 1.0-1.05. Milling the sorbent to increase surface area achieves the same efficiency at a lower NSR, cutting reagent consumption.

At what temperature does the system operate?

Lime-based DSI typically runs at 140-180°C, activated sodium bicarbonate above about 140°C, and semi-dry SDA at 15-20°C above the water dew point (~140-160°C). The temperature window matters both for reaction kinetics and to avoid condensation/corrosion in the downstream bag filter.

Can acid gas removal be integrated with my existing bag filter?

Yes. Sorbent injection is typically added upstream of the existing bag filter, and the reaction products are captured on the filter media. The filtration area and pressure-drop margin should be re-evaluated for the additional sorbent load.

Are pollutants other than SO2 also removed?

Yes. HCl and HF are removed faster and at higher efficiency than SO2. By adding activated carbon on the same line, dioxins/furans, mercury, and other heavy metals can be co-controlled — a common approach especially in waste-incineration applications.

Is there an acid gas removal system manufacturer in Turkey?

Yes, MDSJ Process designs, manufactures, installs, and commissions acid gas removal systems (DSI, semi-dry, and wet routes) in Turkey under the DUCON brand. Active since 1986, it delivers the silo, dosing, reaction duct, and bag-filter integration from a single source.

Quick Info

Neutralizes SO2, HCl, and HF acid gases with a sorbent — dry, semi-dry, or wet route

60-99% acid gas removal efficiency depending on route and sorbent (for SO2)

Typically operates together with a bag filter; solid reaction products are captured downstream

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