Request Engineering Sizing<\/a><\/p>\n<\/div>\n<\/header>\n <\/p>\n\n\u2699\ufe0f Executive Engineering Brief<\/h2>\n\n
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\ud83c\udf0a Processing Capacity<\/h3>\n\n- \ud83d\udcc9 Gas Volume:<\/strong> 10,000 to 1,000,000 m3\/h<\/li>\n
- \ud83c\udf21\ufe0f Allowable Gas Temp:<\/strong> <= 180 \u00b0C<\/li>\n
- \ud83c\udf2b\ufe0f Inlet Sulfur Density:<\/strong> 1 to 1000 mg\/Nm3<\/li>\n
- \u2696\ufe0f Casing Pressure:<\/strong> -6000 to +6000 Pa<\/li>\n<\/ul>\n<\/div>\n
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\ud83c\udfaf Purification Performance<\/h3>\n\n- \u2705 Outlet Emission:<\/strong> < 35 mg\/Nm3<\/li>\n
- \u2705 Operating Resistance:<\/strong> 800 to 1300 Pa<\/li>\n
- \u2705 Scaling Risk:<\/strong> Near Zero (Clear Liquid)<\/li>\n
- \u2705 System Availability:<\/strong> > 98%<\/li>\n<\/ul>\n<\/div>\n
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\ud83c\udfed Ideal Applications<\/h3>\n\n- \ud83c\udfd7\ufe0f Space-Constrained Sites:<\/strong> Compact footprint<\/li>\n
- \ud83d\udd25 Medium\/Small Boilers:<\/strong> Industrial heating<\/li>\n
- \u2697\ufe0f Complex Flue Gas:<\/strong> Low\/Medium Sulfur<\/li>\n
- \u267b\ufe0f Byproduct Recovery:<\/strong> Sodium Sulfate recovery viable<\/li>\n<\/ul>\n
<\/p>\n<\/div>\n<\/div>\n<\/section>\n\n\ud83d\udcca Deep Technical Specifications (BLDJ1W\/100W Series)<\/h2>\n
The Ever-power Single Alkali Desulfurization system is meticulously engineered to provide maximum SO2 mass transfer in a highly compact absorption tower. Below is the comprehensive structural and performance matrix.<\/p>\n
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\n\n\n| Technical Parameter<\/th>\n | Specification Range<\/th>\n | Engineering Impact & Plant Value<\/th>\n<\/tr>\n<\/thead>\n |
\n\nGas Processing Volume<\/strong><\/td>\n| 10,000 – 1,000,000 m3\/h<\/td>\n | Perfectly scaled for industrial boilers, kilns, and medium-sized power units where large FGD plants are economically unviable.<\/td>\n<\/tr>\n | \nAllowable Gas Temperature<\/strong><\/td>\n| <= 180 \u00b0C<\/td>\n | Handles typical industrial exhaust temperatures directly, minimizing the need for extensive upstream evaporative cooling equipment.<\/td>\n<\/tr>\n | \nAllowable Inlet SO2 Concentration<\/strong><\/td>\n| 1 – 1000 mg\/Nm3<\/td>\n | Optimized for medium to low-sulfur coal or specific industrial chemical off-gases.<\/td>\n<\/tr>\n | \nShell Design Pressure<\/strong><\/td>\n| -6000 to +6000 Pa<\/td>\n | Robust carbon steel casing ensures absolute structural integrity under fluctuating induced draft (ID) fan pressures.<\/td>\n<\/tr>\n | \nOperating System Resistance<\/strong><\/td>\n| 800 to 1300 Pa<\/td>\n | Maintains a low pressure drop across the spray layers and demister, preserving ID fan power and lowering continuous OPEX.<\/td>\n<\/tr>\n | \nGuaranteed Outlet Emission<\/strong><\/td>\n| < 35 mg\/Nm3<\/td>\n | Ensures absolute compliance with the strictest local and global environmental standards, preventing operational shutdowns.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<\/section>\n\n\ud83d\udd2c Process Chemistry & Internal Architecture<\/h2>\n\n \n The Single Alkali Working Principle<\/h3>\nThe Single Alkali process utilizes a highly soluble sodium-based absorbent (typically Sodium Hydroxide NaOH or Sodium Carbonate Na2<\/sub>CO3<\/sub>) to react with sulfur dioxide in the flue gas. Because sodium salts are highly soluble, the absorption takes place in a “clear liquid” state, completely eliminating the scaling and blockages that plague calcium-based systems inside the tower.<\/p>\nCore Chemical Reactions (Using NaOH):<\/strong><\/p>\n\n- Hydration:<\/strong> SO2<\/sub> + H2<\/sub>O \u21cc H2<\/sub>SO3<\/sub><\/li>\n
- Primary Absorption:<\/strong> H2<\/sub>SO3<\/sub> + 2NaOH = Na2<\/sub>SO3<\/sub> + 2H2<\/sub>O (Forms sodium sulfite)<\/li>\n
- Excess Absorption:<\/strong> H2<\/sub>SO3<\/sub> + Na2<\/sub>SO3<\/sub> = 2NaHSO3<\/sub> (Forms sodium bisulfite when SO2<\/sub> is in excess)<\/li>\n<\/ol>\n
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\n Internal Component Configuration<\/h3>\nThe BLDJ1W series absorption tower is designed for maximum gas-liquid contact time and mist elimination:<\/p>\n \n- Absorber Body:<\/strong> Constructed of heavy-duty Carbon Steel with an interior lining of anti-corrosion Glass Flake coating to withstand the acidic environment.<\/li>\n
- Slurry Spray Layers:<\/strong> Composed of advanced atomizing spray layers equipped with high-efficiency Silicon Carbide (SiC) nozzles. Droplets are controlled to 200 to 500 microns, maximizing the specific surface area for the chemical reaction.<\/li>\n
- Multi-Stage Demister:<\/strong> Features two stages of high-efficiency demisters with an automated flushing system. Flue gas is forced through curved channels, separating entrained liquid droplets via inertia and gravity before exiting the stack.<\/li>\n
- Circulation & Wash Pumps:<\/strong> Special desulfurization pumps featuring polymer-lined casings and wear-resistant impellers ensure continuous, stable liquid delivery.<\/li>\n<\/ul>\n
<\/p>\n<\/div>\n<\/div>\n<\/section>\n\n\ud83d\ude80 Strategic Engineering Advantages<\/h2>\n\n \n Zero Internal Scaling<\/h3>\nBecause the sodium-alkali absorption liquid is completely clear and free of suspended solid calcium, the spray nozzles and demister blades will never scale or clog. This ensures the tower runs continuously without maintenance shutdowns.<\/p>\n<\/div>\n \n Ultra-Fast Reaction Kinetics<\/h3>\nSodium alkali has a reaction rate with SO2 that is significantly higher than limestone (calcium carbonate). This allows for a much lower Liquid-to-Gas (L\/G) ratio, meaning smaller circulation pumps, less power consumption, and a smaller tower height.<\/p>\n<\/div>\n \n Compact Space Footprint<\/h3>\nDesigned specifically for retrofitting existing facilities, the Single Alkali system requires minimal land area. It bypasses the need for massive limestone preparation silos and complex gypsum dewatering systems.<\/p>\n<\/div>\n <\/p>\n<\/div>\n<\/section>\n\n\u26a0\ufe0f Why Upgrade? Overcoming Industry Bottlenecks<\/h2>\n\n \n The Clogging Crisis of Small Calcium Systems<\/h3>\nMany small-to-medium plants attempted to use miniature limestone-gypsum systems to save money. The result? Severe scaling. Calcium sulfate hardens inside the spray nozzles and demisters, causing catastrophic blockages. This forces the plant to shut down the boiler frequently to physically chip away the scale, leading to massive production losses.<\/p>\n<\/div>\n \n Relentless Regulatory Penalties<\/h3>\nEnvironmental authorities demand continuous, unbroken SO2 compliance (< 35mg\/Nm3). If a poorly designed FGD system trips or clogs, SO2 spikes are instantly recorded by the CEMS (Continuous Emission Monitoring System). This triggers automated, exorbitant fines and risks the revocation of your operating license.<\/p>\n<\/div>\n<\/div>\n<\/section>\n\n\ud83c\udfed Typical Application Scenarios & Industry Fit<\/h2>\nThe BLDJ1W\/100W Series is the preeminent choice for applications where space is tight, and reliability is non-negotiable.<\/p>\n \n \n Industrial Steam Boilers<\/h3>\nIdeal for textile, paper, and food processing plants utilizing medium\/small coal-fired or biomass boilers where land for a large FGD plant is physically unavailable.<\/p>\n<\/div>\n \n Chemical & Metallurgical Kilns<\/h3>\nTreats off-gases from specific chemical roasting, glass manufacturing, or ceramic kilns that produce low-to-medium sulfur concentrations but require ultra-high availability.<\/p>\n<\/div>\n \n Projects Requiring Na2SO4 Recovery<\/h3>\nIn regions or industries where Sodium Sulfate (Na2SO4) has resale value (e.g., glass or detergent manufacturing), the single alkali method turns waste into a profitable byproduct.<\/p>\n<\/div>\n<\/div>\n<\/section>\n\n\u2696\ufe0f Core Advantages: Single Alkali vs. Limestone-Gypsum<\/h2>\n\n \n\n\n| Comparison Metric<\/th>\n | Ever-power Single Alkali (Na)<\/th>\n | Limestone-Gypsum (Ca)<\/th>\n<\/tr>\n<\/thead>\n | \n\nScaling & Blockage Risk<\/strong><\/td>\nZero. Absorbs via clear liquid.<\/strong><\/td>\n| High risk in poorly managed small systems.<\/td>\n<\/tr>\n | \nSystem Footprint (Space)<\/strong><\/td>\nVery Small. No slurry prep\/dewatering needed.<\/strong><\/td>\n| Large. Requires ball mills, vacuum belts, and silos.<\/td>\n<\/tr>\n | \nInitial Capital Expenditure (CapEx)<\/strong><\/td>\nLow. Simplified equipment matrix.<\/strong><\/td>\n| High. Complex mechanical requirements.<\/td>\n<\/tr>\n | \nL\/G Ratio (Pumping Power)<\/strong><\/td>\nLow (Typically 1-3 L\/m3). High reactivity.<\/strong><\/td>\n| High (Typically 10-15 L\/m3). High power consumption.<\/td>\n<\/tr>\n | \nBest Application Range<\/strong><\/td>\nSmall\/Medium gas volume, Low\/Med Sulfur.<\/strong><\/td>\nUtility-scale power plants, High Sulfur.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<\/section>\n\n\ud83c\udfc6 Why Partner with Ever-power?<\/h2>\n\n \n For over 20 years, Ever-power has been the trusted authority in heavy industrial air purification. Our BL series is a technologically mature solution honed through decades of field application.<\/p>\n \n- \u2714\ufe0f<\/span> Full Value-Chain Integration:<\/strong> We don’t just sell parts. We provide Process Engineering \u2794 Precision Manufacturing \u2794 Site Installation \u2794 Intelligent Commissioning.<\/li>\n
- \u2714\ufe0f<\/span> Proven by Industry Giants:<\/strong> Our FGD systems successfully safeguard the compliance of massive conglomerates, including Tongchuan Shengwei<\/em>, Shanshui Group<\/em>, and Huarun Power<\/em>.<\/li>\n
- \u2714\ufe0f<\/span> Uncompromised Quality:<\/strong> Fully ISO certified, holding numerous environmental patents, ensuring every tower meets rigorous pressure and anti-corrosion standards.<\/li>\n<\/ul>\n<\/div>\n<\/div>\n<\/section>\n\n
\ud83d\udcd0 Engineering Selection Guide: Sizing Your FGD<\/h2>\nTo engineer the precise Single Alkali system for your facility, our technical team requires specific operational data. Prepare the following parameters for a rapid technical proposal:<\/p>\n\n1. Flue Gas Volumetrics & Temperature<\/summary>\nProvide the Maximum Gas Volume (Nm3\/h)<\/strong> and the continuous Operating Temperature (\u00b0C)<\/strong>. The BLDJ1W series handles up to 180\u00b0C directly. If your gas is hotter, we will engineer a quench cooling section at the inlet.<\/p>\n<\/details>\n\n2. Inlet Contaminant Profile (Crucial)<\/summary>\nWe need the Inlet SO2 Concentration (mg\/Nm3)<\/strong> and the current dust load. Knowing the maximum sulfur peak allows us to size the circulation pumps and determine the required sodium alkali consumption rates accurately.<\/p>\n<\/details>\n\n3. Target Emission & Site Constraints<\/summary>\nConfirm your local regulatory SO2 target (e.g., < 35mg\/Nm3). Additionally, provide the maximum allowable footprint (Length x Width) available at your site. The Single Alkali system is highly adaptable, and we can configure the tank layout to fit extremely tight spaces.<\/p>\n<\/details>\n<\/section>\n\n\ud83d\udcb0 Value Quantified: Return on Investment (ROI)<\/h2>\nThe Ever-power Single Alkali system presents the lowest total cost of ownership for small-to-medium scale applications.<\/p>\n \n \n The Cost of the Wrong System<\/h3>\n\n- Maintenance Bleed:<\/strong> Forcing a limestone system into a small application leads to constant nozzle scaling. The labor cost of cleaning, combined with boiler downtime, destroys profitability.<\/li>\n
- High CapEx:<\/strong> Building ball mills, slurry tanks, and vacuum filters for a small 50,000 m3\/h boiler is an immense waste of capital.<\/li>\n<\/ul>\n<\/div>\n
\n The Ever-power Upgrade ROI<\/h3>\n\n- CapEx Slashed:<\/strong> The system requires no complex grinding or dewatering equipment, reducing the initial investment by up to 40% compared to equivalent wet calcium systems.<\/li>\n
- 100% Uptime:<\/strong> The clear-liquid absorption means zero scaling. Your boiler stays online, ensuring continuous production and absolutely zero environmental fines.<\/li>\n<\/ul>\n<\/div>\n<\/div>\n<\/section>\n\n
\ud83c\udf0d Global Case Studies: Proving Our Authority<\/h2>\n\n \n \ud83c\uddfb\ud83c\uddf3 Hanoi Textile Manufacturing (Vietnam)<\/h3>\nApplication:<\/strong> 75 t\/h Coal-fired Steam Boiler<\/p>\nChallenge:<\/strong> The plant was located in a dense urban zone with zero space for a large FGD plant, facing imminent shutdown due to new SO2 regulations.<\/p>\nSolution:<\/strong> Ever-power engineered a compact BLDJ100W Single Alkali system. The entire footprint required less than 40m2. Outlet SO2 stabilized at 25 mg\/Nm3, saving the plant from closure.<\/p>\n<\/div>\n\n \ud83c\uddee\ud83c\uddf3 Gujarat Chemical Works (India)<\/h3>\nApplication:<\/strong> Chemical Roasting Kiln Exhaust<\/p>\nChallenge:<\/strong> Fluctuating sulfur loads causing severe scaling in their old calcium-based scrubber, leading to weekly maintenance halts.<\/p>\nSolution:<\/strong> Retrofitted with our Single Alkali system using NaOH. The “clear liquid” absorption immediately ended all scaling issues. Boiler uptime increased to 99.5%, and maintenance costs dropped by 80%.<\/p>\n<\/div>\n\n \ud83c\udde8\ud83c\uddf3 Shaanxi Regional Heating Unit (China)<\/h3>\nApplication:<\/strong> 2x 35 t\/h Winter Heating Boilers<\/p>\nChallenge:<\/strong> Required ultra-low emissions (<35mg) but possessed limited budget and extreme space constraints.<\/p>\nSolution:<\/strong> A single shared BLDJ1W absorber tower was designed for both boilers. The high reactivity of the sodium alkali ensured compliance during peak winter firing without requiring a massive tower.<\/p>\n<\/div>\n\n \ud83c\udde7\ud83c\uddf7 Sao Paulo Food Processing (Brazil)<\/h3>\nApplication:<\/strong> Biomass\/Bagasse Boiler<\/p>\nChallenge:<\/strong> Needed an easy-to-operate system with low pumping power to maintain the factory’s overall green energy efficiency profile.<\/p>\nSolution:<\/strong> The low L\/G ratio of our Single Alkali system meant much smaller circulation pumps were required. The system consumed 40% less parasitic electricity than a standard scrubber while eliminating SO2.<\/p>\n<\/div>\n<\/div>\n<\/section>\n\n\u2753 Engineering & Operational FAQ<\/h2>\n\nWhy choose Single Alkali over Limestone-Gypsum?<\/summary>\nLimestone-Gypsum is excellent for massive utility power plants. However, for industrial boilers (< 1,000,000 m3\/h), the CapEx is too high, it requires a huge footprint, and scaling is a major risk. Single Alkali uses highly reactive, highly soluble sodium (NaOH\/Na2CO3), meaning zero scaling, smaller towers, and much lower initial costs.<\/p>\n<\/details>\n\nIsn’t the operating cost (reagent) higher for sodium?<\/summary>\nYes, sodium hydroxide or sodium carbonate costs more per ton than raw limestone. However, for low-to-medium sulfur applications, the absolute amount of reagent used is small. When you factor in the massive savings from lower CapEx, lower fan power, and zero scaling maintenance, the Single Alkali method is vastly more economical for small\/medium units.<\/p>\n<\/details>\n\nHow does the system prevent secondary pollution from the byproduct?<\/summary>\nThe primary byproduct is a sodium sulfite\/sulfate solution. Depending on local regulations, this can be directed to the plant’s existing industrial wastewater treatment facility, or sent to an evaporation\/crystallization unit to recover solid Sodium Sulfate (Na2SO4), which can be sold to glass or detergent manufacturers.<\/p>\n<\/details>\n\nDoes this tower also remove particulate dust?<\/summary>\nWhile the spray layers will physically knock down a portion of suspended particulate (functioning as a wet scrubber), the primary purpose of this tower is chemical gas desulfurization. We highly recommend installing a Baghouse Dust Collector or Dry ESP upstream of this tower to handle the bulk dust load.<\/p>\n<\/details>\n\n | | | | | | | | | | |
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