Flowvision is one of the leading suppliers of NOx abatement technology to the world’s cement producers. We have leveraged our in-house knowledge of cement kilns with our unique SNCR technology to offer the cement industry cost effective solutions to meet new stringent emission
requirements.

NOx emissions from cement plants are a significant environmental concern due to their adverse effects on air quality and human health. Cement production is a major industrial source of NOx emissions globally. These emissions result from the high-temperature combustion of fossil fuels, such as coal, oil, or natural gas, in the cement kilns. Typically, their concentration ranges from 500 to 1,500 parts per million by volume (ppmv), which is equivalent to 670 to 2,000 milligrams per normal cubic meter (mg/Nm3).

One of the keys success factors is the ability to achieve high NOx reduction efficiencies while limiting the reagent consumption and at the same time making a robust and built to last system.

The formation of NOx in cement plants can be attributed to two primary sources: thermal NOx and fuel NOx.

1. Thermal NOx: Thermal NOx is formed when nitrogen in the combustion air reacts with oxygen at high temperatures. The combustion process in cement kilns, particularly in the burning zone, where temperatures can exceed 1200°C, provides an environment conducive to thermal NOx formation. Kilns with high heat loads and long wet kilns are
   more likely to produce elevated levels of thermal NOx.
2. Fuel NOx: Fuel NOx is generated when nitrogen-containing
   compounds present in the fuel, such as coal or oil, chemically react with oxygen during combustion. The nitrogen content in the fuel, as well as the combustion temperature (typically in the range of 850-950°C), influence the formation of fuel NOx. Kilns with precalciners and without hot spots are known to contribute to fuel NOx emissions.

For Cement plants, the most common NOx abatement system used are the SNCR system (Selective Non-Catalytic reduction). There are two main
issues why the SCR system (Selective Catalytic reduction), often become a very expensive solution:

1. Extreme Dust Load: Cement plants produce flue gas with an exceptionally high concentration of dust. This dust is highly abrasive and can damage or degrade the DeNOx catalyst. It poses a significant challenge to maintaining the catalyst’s effectiveness and longevity.
2. Catalyst Poisoning: The dust in cement plant flue gas contains various elements that can “poison” or deactivate the DeNOx catalyst. These elements can chemically interact with the catalyst’s active sites, reducing its ability to facilitate the NOx reduction reaction effectively. This poisoning effect further complicates the DeNOx process in cement plants.

One of the keys success factors is the ability to achieve high NOx reduction efficiencies while limiting the reagent consumption and at the same time making a robust and built to last system. Flowvision NOx abatement systems have been installed in all the main cement plant types, including;