6. vasarevicius air treatment plastep 2012
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Part-financed by the European Union (European Regional Development Fund
COMPARISON OF DIFFERENT AIR TREATMENT METHODS
WITH PLASMA TREATMENT
PlasTEP 3rd Summer school and trainingscourse 2012 Vilnius / Kaunas
Saulius Vasarevicius, VGTU
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Stationary Source Control
• Philosophy of pollution prevention (3P’s) – Modify the process: use different raw materials
– Modify the process: increase efficiency
– Recover and reuse: less waste = less pollution
• Philosophy of end-of-pipe treatment
– Collection of waste streams
– Add-on equipment at emission points
• Control of stationary sources – Particulates
– Gases
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Three Types Of Control
Mechanical
Chemical
Biological
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Particulate Control
(Mechanical)
• Electrostatic precipitator
• Bag house fabric filter• Wet scrubber
• High efficiency cyclones
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Particulate Control Technologies
• Remember this order: – Settling chambers
– Cyclones
– ESPs (electrostatic
precipitators)
– Spray towers
– Venturi scrubbers
– Baghouses (fabric filtration)
• All physical processes
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Settling Chambers
• “Knock-out pots”
• Simplest, cheapest, no moving parts
• Least efficient
– large particles only
• Creates solid-waste stream
– Can be reused
• Picture on next slide
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Gravity settler
Disadvantages
• Large space requirement
• Relatively low overall collection
efficiencies (typical 20 - 60 %)
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Flue Gas Cleaning – The state of the art
Selection criteria
ESP Bag house Scrubber Cyclones
(normal)
Spraycone
Cyclones
Emissionmg/Nm3 100 30 200 250 < 100
Reliability ++ + ++ ++++ ++++
Cost ++++ ++++ +++ + +
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Gas Cleaning – The state of the art
Evaluation of ESP for industrial boilers:
• High cost (investment, maintenance & operation)• Complex large size plant with sub-systems
• Requires constant gas conditions (sulphur, temp, moisture)
Evaluation of bag filters for industrial boilers:
• High cost (investment, maintenance & filter bags)• Difficult to handle sulphur and sparks
• Not robust (one faulty bag destroys efficiency
Evaluation of wet scrubbers for industrial boilers:• High cost (large water treatment plant)• Difficult to separate fine particulate
• Sulphur control costly & difficult
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Flue Gas Cleaning – The state of the art
Evaluation of cyclone “grid arrestor” :
• Low collection efficiency due to:
• Wrong design (see velocity analysis)
• Air ingress
• Bad manufacturing quality
• Lack of maintenance (blockage of cyclone cells)
But cyclone system advantages are low cost and robust installation
Can a cyclone reach efficiencies of ESP / Bag filter / Wet scrubber?
This question triggered our cyclone development Programin 1994 to improve cyclone efficiency and to invent the
“dry spray agglomeration principle”
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Cyclone
•Most Common
•Cheapest
•Most Adaptable
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Mechanical ollectors
yclones
Advantages: Good for larger PM
Disadvantages: Poor efficiency for finer PM
Difficult removing sticky or wet PM
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Cyclone Operating Principle
“Dirty” Air Enters The Side.
The Air Swirls Around TheCylinder And Velocity IsReduced.
Particulate Falls Out Of The AirTo The Bottom Cone And Out.
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Flue Gas Cleaning – The state of the art
Commercial applications of high efficiency cyclones:
BurnerMax
Fluidized bed furnace
High efficiency cyclonesoperating at 400 C
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Multiple Cyclones
(Multi clone)Smaller Particles Need Lower
Air Flow Rate To Separate.Multiple Cyclones AllowLower Air Flow Rate, CaptureParticles to 2 microns
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Air Filtration
Filt ti M h i
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Filtration Mechanisms• Diffusion
Q: How does efficiency change withrespect to d p?
a. Efficiency goes up as dp decreases
b. Efficiency goes down as dp decreases
Filt ti M h i
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Filtration Mechanisms• Impaction
Q: How does efficiency changewith respect to d p?
a. Efficiency goes up as dp decreases
b. Efficiency goes down as dp decreases
Filt ti M h i
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Filtration Mechanisms• Interception
Fat Man’s Misery,Mammoth Cave NP
http://www.geocities.com/wrique2002/ParentsVisit/FatmansMisery2.jpg
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Filter efficiency for individual mechanismand combined mechanisms
dp (m)
0.01 0.1 1 10
E f f i c
i e n c y
0.0
0.2
0.4
0.6
0.8
1.0
Interception
ImpactionDiffusion
Gravitation
Total
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FILTRATION
Fiber filter
Q: Do filters function just as a strainer,
collecting particles larger than the strainer
spacing?a: yes
b: no
Filt D M d l
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Filter Drag Model
s p f P P P P
V LVt K V K 21
Areal Dust Density LVt W
Filter drag
V
P S W K K S 21
K s
K e
K e & K s to be determined empirically
P f : fabric pressure drop P f : particle layer pressure drop
P s: structure pressure drop
Time(min)
P, Pa
0 150
5 380
10 505
20 610
30 690
60 990Q: What is the pressure drop after 100 minutes of
operation? L = 5 g/m3 and V = 0.9 m/min.
se
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Case A: Pore blocking
Case B: Pore plugging
Case C1: Pore narrowing
Case C2: Pore narrowing w/lost poreCase D: Pore bridging
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Air Filtration
• Impaction
• Diffusion
• Straining (Interception)• Electrostatics
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Fabric Filter
(Baghouse)
•Same Principle As Home
Vacuum Cleaner•Air Can Be Blown Through Or
Pulled Through
•Bag Material Varies AccordingTo Exhaust Character
B
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Cleaned gas
Dirty gas
Baghouse Filter –
only one to remove hazardous fine particles
Dust discharge
Bags
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Advantages/Disadvantages
• Very high collection efficiencies
• Pressure drop reasonably low (at beginning of operation,
must be cleaned periodically to reduce)
• Can’t handle high T flows or moist environments
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Pulse-Air-Jet Type
Baghouse
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About Baghouses
Efficiency Up To 97+%
(Cyclone Efficiency 70-90%)Can Capture Smaller ParticlesThan A Cyclone
More Complex, Cost More ToMaintain Than Cyclones
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Electrostatic Precipitators
Types include:
• Dry, negatively charged
• Wet-walled, negatively charged
• Two-stage, positively charged
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• ELECTROSTATIC PRECIPITATOR
• Advantages of Electrostatic Precipitators
Electrostatic precipitators are capable very high efficiency, generally ofthe order of 99.5-99.9%.
Since the electrostatic precipitators act on the particles and not on the air,they can handle higher loads with lower pressure drops.
They can operate at higher temperatures.
The operating costs are generally low.
• Disadvantages of Electrostatic Precipitators
The initial capital costs are high.
Although they can be designed for a variety of operating conditions, theyare not very flexible to changes in the operating conditions, onceinstalled.
Particulate with high resistivity may go uncollected.
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Electrostatic Precipitator Drawing
H A ESP O t
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How An ESP Operates
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ESPs
• Electrostatic precipitator• More expensive to install,
• Electricity is major operating cost
• Higher particulate efficiency than
cyclones
• Can be dry or wet• Plates cleaned by rapping
• Creates solid-waste stream
• Picture on next slide
El t t ti P i it t C t
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Electrostatic Precipitator Concept
El t t ti P i it t
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Electrostatic Precipitator
Cl d
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Electrostatic Precipitator –
static plates collect particles
Dirty gas
Dust discharge
Electrodes
Cleaned gas
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Scrubbers
•Gas Contacts A Liquid Stream
•Particles Are Entrained In
The Liquid•May Also Be A Chemical
Reaction
–Example: Limestone SlurryWith Coal Power Plant Flue Gas
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Wet Particle Scrubbers
• Particulate control by impaction,
interception with water droplets
• Can clean both gas and particle
phases
• High operating costs, high
corrosion potential
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• WET SCRUBBERS (CONTD.)
•Advantages of Wet Scrubbers
• Wet Scrubbers can handle incoming streams at high temperature, thusremoving the need for temperature control equipment.
Wet scrubbers can handle high particle loading.
Loading fluctuations do not affect the removal efficiency.
They can handle explosive gases with little risk.
Gas adsorption and dust collection are handled in one unit.
Corrosive gases and dusts are neutralized.
• Disadvantages of Wet Scrubbers High potential for corrosive problems
Effluent scrubbing liquid poses a water pollution problem.
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Venturi Scrubber
Detail illustrates cloud atomization from high-velocity gas stream shearing liquid atthroat
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V ti l V t i S bb
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Vert ical Ventur i Scrubber
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Tower Scrubber
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Spray Towers
• Water or other liquid “washes out” PM
• Less expensive than ESP but more than
cyclone, still low pressure drop
• Variety of configurations
• Higher efficiency than cyclones
• Creates water pollution stream• Can also absorb some gaseous
pollutants (SO2)
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Spray Tower
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Gaseous Pollutant Control
• Absorption
• Adsorption
•Combustion
Control of Air Pollutants
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Control of Air Pollutants
Gaseous pollutants - Combustion• 3 types of combustion systems commonlyutilised for pollution control
– direct flame, – thermal, and
– catalytic incineration systems
Control of Air Pollutants
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Control of Air Pollutants
Gaseous pollutants - Adsorption
• physical adsorption to solid surfaces
• Reversible - adsorbate removed from theadsorbent by increasing temp. or lowering
pressure• widely used for solvent recovery in dry
cleaning, metal degreasing operations,
surface coating, and rayon, plastic, andrubber processing
Control of Air Pollutants
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Control of Air Pollutants
Gaseous pollutants - Adsorption• limited use in solving ambient air pollutionproblems – with its main use involved in the
reduction of odour
• Adsorbents with large surface area to
volume ratio (activated carbon) preferred
agents for gaseous pollutant control
• Efficiencies to 99%
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Carbon Adsorption
• Will do demonstration shortly
• Good for organics (VOCs)
• Both VOCs and carbon can berecovered when carbon is
regenerated (steam stripping)
• Physical capture
– Adsorption
– Absorption
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Control of Air Pollutants
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Control of Air Pollutants
Gaseous pollutants - Absorption
• Scrubbers remove gases by chemical
absorption in a medium that may be a liquid
or a liquid-solid slurry
• water is the most commonly used scrubbing
medium
• Additives commonly employed to increasechemical reactivity and absorption capacity
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Pollutants Of Interest
•Volatile Organic Compounds
(VOC)•Nitrogen Oxides (NOx)
•Sulfur Oxides (SOx)
Controlling Gaseous Pollutants: SO2 &
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Controlling Gaseous Pollutants: SO2 &NOx
• Modify Process (recall 3P’s)
– Switch to low-sulfur coals
– Desulfurize coal (washing, gasification)
• Increase efficiency – Low-NOx burners
• Recover and Reuse (heat)
– staged combustion – flue-gas recirculation
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Flue Gas SOx Control
SOx Forms Sulfuric Acid WithMoisture In Air Producing
Acid Rain.Remove From Flue Gas ByChemical Reaction With
Limestone
Control Technologies for Nitrogen
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Control Technologies for Nitrogen
Oxides
• Preventive – minimizing operating
temperature
– fuel switching
– low excess air – flue gas recirculation
– lean combustion
– staged combustion
– low Nox burners
– secondary combustion – water/steam injection
• Post combustion – selective catalytic reduction
– selective non-catalyticreduction
– non-selective catalyticreduction
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Thermal Oxidizers
For VOC Control
Also Called Afterburners
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Thermal Oxidation
• Chemical change = burn – CO2 and H2O ideal end products of all processes
• Flares (for emergency purposes)
• Incinerators
– Direct
– Catalytic = improve reaction efficiency
– Recuperative: heat transfer between inlet /exit gas
– Regenerative: switching ceramic beds that hold
heat, release in air stream later to re-use heat
T T Of O idi
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Two Types Of Oxidizer
•Catalytic
•Non-Catalytic
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Thermal Oxidizer
(Non-Catalytic)
C l i Th l O idi
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Catalytic Thermal Oxidizer
Biological Method
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Biological Method
•Uses Naturally OccurringBacteria (Bugs) To BreakDown VOC
• “Bugs” Grow On Moist MediaAnd Dirty Gas Is Passed
Through. Bugs Digest TheVOC.
•Result Is CO2 And H2O
A Bi Filt F VOC R l
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A Bio Filter For VOC Removal
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E-beam flue gas treatment process
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E beam flue gas treatment process(Prof. A.Chmielewski)
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Pollutants removed by EB method
The method has been designed for simultaneous removal of:
• SO2
• NOx
• Cl, HF etc.
• Volatile Organic Hydrocarbons (VOC)• Dioxins
• Mercury
• Others…
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Electron beam effect on gas, primary radiolysis products:
• 4.43N2 -› 0.29N2* + 0.885N(2D) + 0.295N(2P) + 1.87N(4S) + 2.27N2+ +0.69N+ + 2.96e-
• 5.377O2 -› 0.077O2* + 2.25O(1D) + 2.8O(3P) + 0.18O* + 2.07O2+ +
1.23O+ + 3.3e-
• 7.33H2O -› 0.51H2 + 0.46O(3P) + 4.25OH + 4.15H +1.99 H2O+ + 0.01H2+
+ 0.57OH+ + 0.67H+ + 0.06O+ + 3.3e-
• 7.54CO2 -› 4.72CO + 5.16O(3P) + 2.24CO2+ + 0.51CO+ + 0.07C+ +
0.21O+ + 3.03 e-
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Electron beam effect on gas, secondary reactions:
• O(1D) + H2O ͢ ͢ ͢ ͢ -› 2OH*
• N2+ + 2H2O -› H3O+ + OH*+ N2
• O(3P) + O2+ M -› O3+ M
• e-+ O2 + M -› O2-+ M
• H3O+ + O2- -› HO2*+ H2O
As a result of these primary and secondary reactions OH*,
HO2 *, O*radicals, O3and other oxidizing species areformed, that can oxidize NO, SO2 and Hg.
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SO2 removal pathways
Radiothermal:
• SO2 + OH* + M -› HSO3 + M
• HSO3 + O2 -› SO3 + HO2*
• SO3 + H2O -› H2SO4
• H2SO4 + 2NH3 -› (NH4)2SO4
Thermal:
• SO2 + 2NH3 -› (NH3)2SO2• (NH3)2SO2 -› (NH4)2SO4
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NOx removal pathways
NO oxidation
• NO + O(3P) + M -› NO2+ M
• O(3P) + O2+ M -› O3+ M
• NO + O3+ M -› NO2+ O2+ M
• NO + HO2* + M -› NO2+ OH* +M
• NO + OH* + M -› HNO2+M
• HNO2+ OH* -› NO2+ H2O
NO2removal• NO2+ OH* + M -›HNO3+ M
• HNO3+ NH3-›NH4NO3
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Reaction mechanisms and sequenceof E-beam process
H. Namba: Materials of UNDP(IAEA)RCA Regional Training Course on
Radiation Technology for Environmental Conservation TRCE-JAERI,
Takasaki,
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VOC-decomposition and deodorization methods
Thermal Processes: 1-TO, Thermal Oxidation; 2-RTO, Regenerative Thermal Oxidation; 3-
Catalytic Oxidation with Recuperation. Filtering/Adsorption: 4-Biofilters; 5-Scrubber; 7-
Adsorption Container; 8-Concentrator Unit with TO; 9-Filtering. Non-thermal Oxidation: 6a-
Electrical Non-thermal oxidation; 6b-UVS Non-thermal Oxidation.
VOC d iti
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VOC-decomposition
Non-thermal plasmas:• Decomposition of contaminants without heating
• Wide range of pollutants (Gases ... Particulate Matter PM)
• Decomposition of organic PM
• High efficiency for low contamination (e.g. deodorization), ([VOCs] < 1 g
Corg/m3)
Negative aspects:
• High energy cost/molecule_ high energy for high concentrations
• Uncompleted conversion and by-products _ low selectivity (CO2)
• Deposition of polymer films in reactors _ unstable plasma source
Possibilities - indirect treatment, hybrid methods = combination of plasma with:
catalysts, scrubbing, adsorbents…
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Non thermal plasma
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PDC for deodorization (commercial)
1200 By-products
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Total weighed environmental impact of plasma and non-plasma end-of-pipe
pollutant treatment technologies: the comparison of technologies for SOx/NOx
removal. 1) Electron Beam Flue Gas Treatment (EBFGT) versus 2) Wet Flue Gas
Desulphurization with Selective Catalytic Reduction (WFGD+SCR
1099.7
74.4
0
200
400
600
800
1000
1200
EBFGT WFGD + SCR
C M L 2 0 0
1 ,
E x p e r t s I K P ( C e n t r a l E u r o p e
)
By products
Material resources
Electricity
Material resources
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Total weighed environmental impact of plasma and non-plasma end-of-pipe
pollutant treatment technologies: the comparison of technologies for VOCs
removal. 1) Dielectric barrier discharge (DBD) versus 2) adsorption by zeolite (for
LCA) and molecular sieves (for CBA), 3) biofiltration,
4.2
41.1
26.1
0
10
20
30
40
C M L
2 0 0 1 ,
E x p e r t s I K P ( C e n t r a l E u r o p e )
Material resources
Electricity
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Flue gas treatment method >300
MW unit
Investment costs
€/kW
Annual operation costs
€/MW
EBFGT
32-45
1290-1577
Wet deSO2 + SCR 176-247 4786-5350
Wet deSO2 + SNCR 144-190 3870-4223
Emission control method 120 MW
unit
Investment costs
€/kW
Annual operation costs
€/MW
EBFGT
113
5167
WFGT+SCR 162 5343
Investment and operation costs of EBFGT and combination of conventional deSO2 and deNOx
Full “Report on Eco-Efficiency of Plasma-Based technologies for Environmental Protection” and
“Report on cost-benefit analysis of plasma-based technologies“ are available at the PlasTEP
project website (http://www.plastep.eu/fileadmin/dateien/Outputs/OP3-2.1_Eco-
efficiency_report.pdf , http://www.plastep.eu/fileadmin/datein/Outputs/120208_CBA.pdf ).
http://www.plastep.eu/fileadmin/dateien/Outputs/OP3-2.1_Eco-efficiency_report.pdfhttp://www.plastep.eu/fileadmin/dateien/Outputs/OP3-2.1_Eco-efficiency_report.pdfhttp://www.plastep.eu/fileadmin/datein/Outputs/120208_CBA.pdfhttp://www.plastep.eu/fileadmin/datein/Outputs/120208_CBA.pdfhttp://www.plastep.eu/fileadmin/dateien/Outputs/OP3-2.1_Eco-efficiency_report.pdfhttp://www.plastep.eu/fileadmin/dateien/Outputs/OP3-2.1_Eco-efficiency_report.pdfhttp://www.plastep.eu/fileadmin/dateien/Outputs/OP3-2.1_Eco-efficiency_report.pdfhttp://www.plastep.eu/fileadmin/dateien/Outputs/OP3-2.1_Eco-efficiency_report.pdfhttp://www.plastep.eu/fileadmin/dateien/Outputs/OP3-2.1_Eco-efficiency_report.pdf
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8/18/2019 6. Vasarevicius Air Treatment PlasTEP 2012
99/99
Thank You for Your attention!
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