A PIONEER IN AIR QUALITY CONTROL FOR POWER AND INDUSTRIAL APPLICATIONS
We have provided our customers with advanced Air Quality Control Systems (AQCS) for more than 80 years. GE’s expertise, technology, and comprehensive product portfolio enable our customers to comply with today’s stringent emission regulations for particulate and gaseous pollutants emitted from power plants and industrial operations. Our high-quality and cost-effective equipment and services can be adapted to our customers’ needs. GE's Air Quality Control Systems also put our Smarter, Cleaner Steam Power initiative into action.
CUSTOMIZED OFFERINGS
With GE, customers receive a wealth of air quality control know-how. For new builds and upgrade and retrofit of existing AQCS, we offer on-demand solutions tailored to meet our customers’ requirements, including partial or full scope as described below:
Engineering: GE offers advanced air pollution control engineering, from process and equipment design to construction, operations, and maintenance.
Equipment supply: Our comprehensive AQCS portfolio of products covers a broad range of pollutants with industry-leading technology with a single process or a combination to cover the entire flue gas chain. This gives customers the flexibility to address complex interactions between components and processes.
Construction and commissioning: We offer:
- Construction management
- Commissioning management
- Construction and commissioning advisory services
Inspection and maintenance: We provide these services for our own fleet and/or other AQCS solutions.
INNOVATIVE PRODUCTS AND TECHNOLOGIES
Since 1983, our technology center in Växjö, Sweden—one of the largest in the world in the field of environmental control solutions—has been at the forefront of advanced research and development for air quality and CO2 control solutions. Focusing on technology innovation and product validation, it has test halls for pilot operations and flow modeling, an analytical laboratory specializing in particle and environmental analyses, an instrument workshop, high voltage facilities for ESP electrical testing (SIR, T/R sets), and a mechanical workshop for pilot equipment manufacturing.
PRODUCTS:
1. PARTICULATE CONTROL: FABRIC FILTERS
- For particulate removal, fabric filters offer a flexible alternative to electrostatic precipitators (ESPs), particularly when dust characteristics are challenging or variable. Lower than 5 mg/Nm3 particulate emissions possible, greater than 99.97% particulates removal efficiency, high PM10 and PM 2.5 removal rate
- Filters up to 12 meters tall for reduced footprint and operational costs
- Large fuel flexibility and ability to handle varying boiler loads
GE offers both high ratio (pulse jet) and low ratio (reverse air) options, depending on the application. Fabric filters may be used stand-alone or integrated in Dry Flue Gas Desulfurization (DFGD) solutions (NID or SDA), for dry scrubbing in the aluminum industry (Abart), or as the principal and polishing filters in mercury control solutions (Mer-Cure or Filsorption).
- Renowned Optipulse filtration technology with gravimetric flow and Optipow plunger valves for efficient bag cleaning
- Stand-alone or integrated in multi-pollutant systems
- Latest EFFIC controller and ProMo software for superior FF performance
- The combination of Optipow valves and EFFIC controller on a new or existing FF provides better bag life compared to other available solutions
2. PARTICULATE CONTROL: DRY AND WET ELECTROSTATIC PRECIPITATORS (ESPS)
GE offers a wide range of robust, cost-effective, and reliable electrostatic precipitator designs for a variety of applications. Discover the advantages of our electrostatic precipitators.
- PROVEN PARTICULATE MATTER REMOVAL: Less than 10 mg/Nm3 emissions.
- DESIGNED FOR PERFORMANCE: Excellent and efficient electrostatic precipitator with lower cost modular systems.
- FOR WET ELECTROSTATIC PRECIPITATORS: Ultra-low particulate emissions (less than 1mg/Nm3), acid mists, aerosols, and hazardous air pollutants (HAP).
Backed by more than 237 GW installed in power generation and more than 70 years of experience on an extended range of fuel combinations and industrial applications, our electrostatic precipitator solutions cater to increasingly strict regulations at a lower life cycle cost.
We offer spiral and rigid designs of emitting electrodes, tumbling hammer, and electric impact rapping systems. Our ESP pollution control devices feature a flexible layout and modular designs. GE also offers integrated ESP control systems, including the latest generation EPIC intelligent controller and the ProMo tool for enhanced ESP performance.
As an alternative to Transformer/Rectifier (T/R) sets, GE also provides Switch Integrated Rectifiers (SIR) for increased power input, lower power consumption, and improved particulate removal efficiency. Our SIRs work well for performance enhancement of existing ESPs.
3. SOX CONTROL: DRY FLUE GAS DESULFURIZATION (DFGD)
Dry flue gas emissions systems have been used for SOx emission and multi-pollutant control for several decades. GE can assist with a boiler flue gas analysis to determine the best approach to lower flue gas emissions.
NOVEL INTEGRATED DESULFURIZATION (NID)
This system is made up of a patented integrated hydrator/mixer, a J-duct reactor, and typically a fabric filter. Hydrated lime is used as a reagent to react with gaseous pollutants like SOx, HCl, and HF. Mercury collection can be realized by injecting PAC upstream. The collected particles are then either recirculated or disposed.
- Our dry flue gas desulfurization systems have over 20 years of successful commercial operation, with more than 50 industrial references and over 15 GW installed globally
- Up to 98% SO2 removal, up to 4% sulfur in fuel, multi-pollutant control
- Compact footprint of less than 50%, compared to Spray Dryer Absorber (SDA)
- Modular and standard design for lower construction costs
- Simple operation and maintenance; low operational costs
- NID is a well-fitted technology for various industry applications, in particular waste-to-energy and iron and steel
SPRAY DRYER ABSORBER (SDA)
This conventional dry FGD system has been widespread for many years. It’s made up of a reactor followed by a fabric filter. In the reactor, the reagent slurry solution is atomized using either GE’s rotary atomizer technology or dual fluid nozzles, and the droplets react with the gaseous pollutants in the flue gas stream.
- 35-plus years of experience, with more than 100 industrial references and 15 GW installed worldwide
- Up to 95% SO2 removal, up to 2.5% sulfur in coal
4. SOX CONTROL: WET FLUE GAS DESULFURIZATION (WFGD)
Wet flue gas desulfurization has been the most common technology for SOx control for more than four decades.
- COVERING WIDE RANGE OF FUELS AND APPLICATIONS - Coal, petcoke, oil, biomass, industries
- PROVEN EXPERIENCE - With more than 100 GW in operation worldwide
- HIGH SO2 REMOVAL RATE - More than 99% achieved using the WFGD OST
GE’s Steam Power Systems wet flue gas desulfurization(WFGD) portfolio consists of the following options: WFGD-Open Spray Tower (OST) The WFGD-OST third generation offers lower power consumption and has smaller dimensions compared to previous versions, while reaching nearly zero emissions. The gypsum by-product recovered is usable as wallboard and is of cement quality. Flowpac WFGD The Flowpac WFGD contains a turbulent bed absorber, in which a flue gas passes through limestone slurry. It is targeted for applications requiring increased SO2 removal efficiency and enhanced SO3 removal efficiency. For power generation, it is designed for unit sizes up to 360 MW with varying fuel conditions, such as sulfur content, which can rise to high levels.
- 15 industrial applications and 58 GW installed in power generation.
- Flexible absorber performance with excellent controllability of the SO2 removal rate.
- Improved performance control through patented sulfite analyzer.
- Fuel flexibility for all types of fuel (including heavy fuel oil) with sulfur content up to 4.5% for WFGD-OST. and up to 6% for Flowpac WFGD.
- Lower power consumption with lower emissions of particulates and aerosols.
Sea Water FGD (SWFGD) Technology
The Steam Power Systems SWFGD is a unique no-by-product SO2 removal solution. Thanks to more than 40 years of experience in SWFGD for power generation and industry applications, GE is one of the world’s leading providers with the biggest SWFGD installed fleet. We use packing to enhance performance and absorber sizing.
- An economical desulfurization solution for plants in coastal areas
- Around 30 industrial applications, with 51 GW in operation or under construction for power generation worldwide
5. NOX CONTROL: SELECTIVE CATALYTIC REDUCTION (SCR)
High NOx reduction rates and system reliability make our flexible and compact selective catalytic reduction technology the right choice for post-combustion NOx emissions control.
- A WEALTH OF EXPERIENCE - 40 industrial references and more than 48 GW installed worldwide for power generation.
- HIGH REDUCTION RATE - Up to 95% NOx emissions removal, low ammonia slip (down to 2 ppm)—so you can meet NOx emissions standards and regulations.
- TECHNOLOGY FOR PERFORMANCE - Proprietary IsoSwirl*mixing technology and specific ammonia injection grid design for improved performance.
6. OTHER AQCS SOLUTIONS: MERCURY, VOC, ZERO LIQUID DISCHARGE
MERCURY
Our Filsorption system uses activated carbon injection upstream of a standard primary or secondary particulate control system.
The Mer-Cure system uses a proprietary approach—injection of sorbent upstream of the air preheaters, for faster oxidation under higher temperatures.
- Over 25 years of experience resulting in more than 20 industrial references and 29 GW installed
- More than 2 million hours of reliable operation
VOLATILE ORGANIC COMPOUNDS (VOC)
For Volatile Organic Compounds (VOC) mitigation, we provide thermal oxidizers and regenerative thermal oxidizers—mature technologies that have been sold for many decades.
SOLUTION FOR ZERO LIQUID DISCHARGE
Additionally, GE offers our Spray Dryer Evaporator (SDE*) solution for plants to achieve Zero Liquid Discharge (ZLD) when operating WFGD technologies.
Our simple and cost-effective SDE technology uses hot flue gas to evaporate waste water. The dissolved or suspended solids are collected in existing particulate removal equipment. With the addition of lime to condition the waste water feed stream, acid gases in the flue gas can be captured as an added benefit.
7. SMALL SIZE AQCS: SMARTLINE SOLUTIONS
GE has developed the Smartline range of products to cater to smaller-sized applications, such as district heating, small power units, thermic fluid heaters, lime kilns, foundries, and metallurgical plants.
FABPAC FABRIC FILTERS FOR PARTICULATE CONTROL
Lower your operational costs and footprint and reduce site installation time with our standardized and modular fabric filters. Our patented Optipow* cleaning valves together with EFFIC controllers provide longer bag life and lower compressed air consumption. FABPAC filters are available in four standardized sizes with various bag lengths and materials.
ELPAC ESPS FOR PARTICULATE CONTROL
The ELPAC ESP adapts the benefits developed on large units to a smaller scale. Key features include: covered service room on top, flat bottom with scraper conveyor, scraper conveyor, Switch Integrated Rectifiers (SIR), efficient construction for easy access, and large gas flow range with one module (7,000-170,000 m3/hr).
MICRO-NID*TECHNOLOGY FOR DRY DESULFURIZATION AND MULTI-POLLUTANT CONTROL
Due to its simple design, our advanced dry desulfurization technology also is available for small-scale applications. With more stringent regulations being progressively extended to smaller units, this type of application is expected to be widely deployed in the coming years.
8. WASTE HEAT RECOVERY & FLUE GAS COOLING
Controlled Flue Gas Cooling & Waste Heat Exchanger Solutions
GE’s waste heat recovery plant solutions aren’t just a way to cut costs and lower emissions, they allow you to recover more energy than you ever thought possible—contributing to a more successful, profitable plant.
Our waste heat exchange technology can cut your costs by:
- Helping you achieve fuel savings for captive power/steam generator through feedwater preheating
- Reducing your specific energy consumption for producing steel, and reducing maintenance costs for the quench tower
- Increasing captive power plant efficiency with the most advanced flue gas energy recovery technology
And lower emissions standards by:
- Lowering emissions of SOx, NOX and CO2 through reduced fuel consumption
- Increasing your captive power plant’s energy efficiency
- Reducing your energy consumption per ton of steel produced
- Minimizing your plant’s environmental load
…all using heat recovery solutions which seamlessly integrates with your existing installation. Our waste heat recovery technology have been proven in other industries to recover up to 30% in previously lost energy.
Waste Heat Exchanger: How it works
See step-by-step how our waste heat exchanger integrates with your existing equipment to save on operating costs.
- Hot flue gas from the furnace is routed through the heat exchanger (HEX) and cooled in a controlled way
- Through this controlled flue gas cooling, dioxin formations are eliminated
- Energy is transferred from flue gas to water
- The recovered flue gas water is routed to existing boiler feedwater preheater or district heating applications
- Dust accumulation is prevented by a proprietary cleaning mechanism that continuously removes dust from tubes, preventing build-up
- The quenching tower cools flue gas quickly to minimize the release of harmful gases. With HEX technology, the use of a quench tower can be reduced, minimizing both maintenance time and costs
- The cooled flue gas is routed to de-dusting equipment
For more details on this process and how it can help you recover valuable energy, please contact GE power today
Recover and reuse waste heat
Improving your plant economics isn’t easy. Here are some results we’ve seen across the iron & steel industry.
To combat the price of iron and steel, we want to help you lower your operating expenses. In the ferro-alloy and ferro-silicon industries we helped improve the economics of the smelter operation with a recovery of up to 30% of the original electrical feed to the smelters.
Other details include:
- The melting energy used in the installation amounted to 70 MWel
- Recovering heat from the smelting exhaust produces 20 MWel. of electricity for internal use (representing recovery of up to 28% of the smelter’s energy consumption)
- In many cases, the payback of the waste heat is proportional to the cost of alternative power production
Source: General Electric
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