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.