Flue Gas Treatment Systems

Flue Gas Treatment Systems

Advanced Emission Control & Environmental Compliance Solutions

Overview

Flue Gas Treatment Systems are critical environmental control units designed to​​ remove harmful pollutants​​ from exhaust gases generated by combustion and thermal processes. These systems ensure compliance with​​ stringent environmental regulations​​ while enabling safe, continuous, and efficient plant operation.

Mechasol designs and delivers​​ integrated flue gas treatment solutions​​ that combine particulate removal, acid gas neutralization, NOx reduction, and toxic compound control into a​​ coordinated, high-performance system​​ tailored to each application.

Engineering Philosophy & System Design

Mechasol approaches flue gas treatment as a​​ process-specific engineering challenge, where gas composition, temperature, flow rate, and regulatory limits dictate the system architecture.

Key design parameters include:

• Flue gas flow rate and temperature profile

• Pollutant composition (dust, SO₂, NOx, HCl, HF, VOCs, heavy metals, dioxins)

• Required emission limits (EU IED, local standards)

• Process continuity and availability targets

• Integration with upstream combustion systems

Each system is engineered to achieve​​ maximum removal efficiency with minimum pressure loss and operating cost.

Particulate Matter Removal Systems

Cyclones & Multi-Cyclones

Used as primary separation stages for coarse particulates.

Advantages

• Simple and robust design

• Low maintenance

• High-temperature capability

Bag Filters (Fabric Filters)

Bag filters provide​​ high-efficiency dust removal, typically achieving >99.9% particulate capture.

Key Features

• Pulse-jet or reverse air cleaning

• Wide fabric selection based on temperature and chemistry

• Modular compartmentalized design for continuous operation

Typical Applications

• Biomass and waste incineration plants

• Cement and mineral processing

• Industrial boilers

Electrostatic Precipitators (ESP)

ESP systems are applied for​​ large gas volumes​​ and continuous-duty applications.

Advantages

• Low pressure drop

• Suitable for high flow rates

• Long service life

Acid Gas Neutralization Systems

Dry & Semi-Dry Scrubbers

Used to neutralize acidic components such as​​ SO₂, HCl, and HF.

Process Media

• Lime (Ca(OH)₂)

• Sodium bicarbonate (NaHCO₃)

Benefits

• Compact layout

• Lower water consumption

• Reduced wastewater generation

Wet Scrubber Systems

Wet scrubbers remove acid gases through​​ gas–liquid contact.

Key Components

• Spray towers or packed columns

• Circulation pumps

• Chemical dosing systems

• Mist eliminators

Wet systems are preferred where​​ high removal efficiency​​ and gas cooling are required.

NOx Reduction Systems

SNCR – Selective Non-Catalytic Reduction

SNCR systems inject ammonia or urea directly into the flue gas at controlled temperatures.

Characteristics

• Moderate NOx reduction

• Lower capital cost

• Simple installation

SCR – Selective Catalytic Reduction

SCR systems achieve​​ high NOx removal efficiency​​ by passing flue gas through a catalyst bed.

Advantages

• NOx reduction up to 90%

• Stable long-term performance

• Compliance with strict emission limits

SCR systems are widely used in​​ power plants, refineries, and large industrial facilities.

Toxic Compound & Odor Control

Activated Carbon Injection

Used to capture:

• Dioxins and furans

• Heavy metals (Hg)

• VOCs and odorous compounds

Activated carbon systems are often combined with bag filters for maximum effectiveness.

Heat Recovery & Gas Conditioning

Flue gas treatment systems can be integrated with:

• Waste Heat Recovery Boilers (WHRB / HRSG)

• Gas coolers and economizers

• Condensers for moisture and acid control

This integration improves​​ overall plant efficiency​​ while protecting downstream treatment equipment.

Automation, Monitoring & Safety

Mechasol flue gas treatment systems include:

• Continuous emission monitoring systems (CEMS)

• PLC / DCS-based control

• Pressure drop and temperature monitoring

• Emergency bypass and safety interlocks

Automation ensures​​ stable operation, regulatory compliance, and operational transparency.

Modular & EPC Delivery Capability

Mechasol delivers flue gas treatment systems as:

• Standalone equipment packages

• Skid-mounted modular units

• Fully integrated EPC turnkey solutions

Scope includes engineering, fabrication, installation, commissioning, and operator training.

Typical Applications

Flue Gas Treatment Systems are applied in:

• Biomass and waste-to-energy power plants

• Waste and sludge incineration facilities

• Oil & gas process heaters and boilers

• Refineries and petrochemical plants

• Industrial furnaces and kilns

Mechasol Value Proposition

• Process-driven, application-specific engineering

• High removal efficiency with optimized operating cost

• Modular, expandable system architecture

• Full compliance with environmental regulations

• EPC and lifecycle support capability

Summary

Mechasol Flue Gas Treatment Systems provide​​ reliable, efficient, and regulation-compliant emission control​​ for modern industrial and energy facilities. By combining advanced separation, neutralization, and reduction technologies, Mechasol enables clients to operate sustainably while maintaining high plant availability and performance.