Case Study: Advanced Ammonia and NOx Scrubbing System in Petrochemical Refinery
Client Overview:
IOCL, a major player in the refinery and petrochemical industry, faced significant challenges with ammonia (NH3) and oxides of nitrogen (NOx) emissions from their catalyst manufacturing unit. The rotary calciner and dryer machines emitted fumes at temperatures ranging from 140 to 240 degrees Celsius, posing environmental compliance and operational efficiency concerns. The existing emission control systems were inadequate to effectively capture and treat these pollutants.
Challenges:
- High-Temperature Emissions: The rotary calciner and dryer machines generated fumes at elevated temperatures, requiring specialized scrubbing solutions capable of handling thermal fluctuations.
- Pollutant Composition: Ammonia and NOx emissions required precise and efficient treatment to meet stringent environmental regulations and emission standards.
- Continuous Monitoring: Lack of real-time data on NOx emissions necessitated the implementation of a continuous stack NOx analyzer for accurate monitoring and control.
Solution:
IOCL partnered with Caramet Technologies Pvt Ltd to design, manufacture, install, and commission an advanced negative pressure Venturi and Packed Bed Scrubbing System equipped with a continuous stack NOx analyzer tailored specifically for their catalyst manufacturing unit.
Implementation Process:
- Detailed Assessment: Caramet Technologies conducted a thorough assessment of IOCL’ catalyst manufacturing processes, focusing on emission points, temperature profiles, and pollutant characteristics (NH3 and NOx).
- System Design and Engineering: Based on the assessment, Caramet Technologies engineered a customized solution featuring:
- Advanced Venturi and Packed Bed Scrubbing Technology: Integrated negative pressure design to optimize pollutant capture efficiency and minimize energy consumption.
- High-Temperature Resistant Materials: Selection of specialized materials capable of withstanding thermal fluctuations and corrosive environments.
- Continuous Stack NOx Analyzer: Implementation of a state-of-the-art analyzer for real-time monitoring and control of NOx emissions, ensuring compliance with regulatory limits.
- Installation and Commissioning: Caramet Technologies managed the installation process with precision, incorporating safety protocols and minimizing downtime. The system was commissioned with extensive testing to validate performance and compliance with environmental standards.
Results:
- Effective Emission Control: The advanced Venturi and Packed Bed Scrubbing System successfully captured and treated NH3 and NOx emissions from the rotary calciner and dryer machines. This significantly reduced pollutant levels and ensured compliance with stringent environmental regulations.
- Initial NOx Load: 5.6 grams per cubic meter (g/m³).
- Initial NH3 Load: 1.73 grams per cubic meter (g/m³).
- Achieved Outlet Emissions for NOx: Below 50 milligrams per normal cubic meter (mg/Nm³).
- Achieved Outlet Emissions for NH3: Below 10 milligrams per normal cubic meter (mg/Nm³).
- Enhanced Operational Efficiency: High-temperature resistant materials and optimized scrubbing technology improved system reliability and longevity, reducing maintenance costs and downtime.
- Real-Time Monitoring and Compliance: The continuous stack NOx analyzer provided accurate, real-time data on NOx emissions, enabling proactive adjustments to maintain compliance and optimize operational performance.
Conclusion:
By partnering with Caramet Technologies and implementing the advanced Venturi and Packed Bed Scrubbing System with a continuous stack NOx analyzer, IOCL successfully addressed emission control challenges in their catalyst manufacturing unit. The solution not only achieved regulatory compliance and environmental stewardship but also enhanced operational efficiency and sustainability. This case study highlights Caramet Technologies’ expertise in delivering innovative environmental solutions tailored to complex industrial requirements.
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