SNCR improvement
A Japanese carbon materials manufacturing plant had issues with clogging of their spray nozzles during the SNCR process as well as insufficient atomization. The clogging caused a serious reduction in productivity as the spray nozzles needed frequent maintenance. At the same time, the insufficient atomization led to issues with increased urea consumption and a need for drainage.
Benefits of SETOJet-R®
- Anti-clogging design
- Fine atomization
- External mixing
- No course particles
The outline of the project:
A Japanese carbon materials manufacturing plant was employing SNCR by spraying steam and urea solution into the exhaust gas using pneumatic spray nozzles.
Selective Non-Catalytic Reduction (SNCR) is a process to prevent atmospheric pollution from nitrogen oxides by directly injecting a reducing agent (urea solution or ammonia gas) into the incinerator without using a catalyst, thereby reducing nitrogen oxides (NOx) to nitrogen (N₂) and water (H₂O).
However, the nozzles used at the time produced inconsistent spray particle sizes. Coarse, unevaporated particles adhered to the incinerator’s inner walls, causing corrosion of the refractory bricks and mortar. In addition, the spray nozzles would frequently clog.
System used for this application
SETOJet-R® Pneumatic spray nozzle
SETOJet-R® is known for its fine atomization with a droplet size between 15–40 μm. In addition, it has a clogging-free design due to its external mixing system.
The solution
Ikeuchi Japan selected the SETOJet-R Series, an externally mixed type offering high resistance to clogging and excellent atomisation performance, proposing it as the optimal nozzle for urea water spraying.
Using the nozzle flow rate diagram, Ikeuchi Japan could demonstrate that no coarse particles were generated and that several benefits were gained:
1) Complete evaporation of the urea solution due to the fine atomization of SETOJet-R. This reduced the adhesion to the furnace walls and thereby the corrosion effect.
2) The complete evaporation of the urea solution also optimises the reduction efficiency of nitrogen oxides.
The result
After implementing SETOJet-R and testing it, it could be concluded that there was no longer a problem with corrosion of bricks and mortar. In addition, the fine atomization and ability to fully evaporate the urea efficiently resulted in a 40% reduction in urea solution consumption. This confirmed an annual cost saving of €5.000.
The customer was very satisfied with the project results and consequently started to implement the same solution in other areas. If you are looking for a similar solution in your facility, please don’t hesistate to contact us.
Advantages of SETOJet-R®
- Fine atomization
- Anti-clogging
- Full evaporation
- Cost-efficient
- Increased productivity
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