Waste-to-Energy Plant: Bicarmill® 800 for Acid Gas Removal from Flue Gases

In the air pollution control sector, one of the most critical challenges is the removal of acid gases produced by the combustion of municipal and industrial waste.
Gases such as hydrogen chloride (HCl) and sulfur oxides (SOx) must be efficiently neutralised to comply with increasingly stringent international and European emission limits. Sodium bicarbonate is commonly used as a dry sorbent due to its high reactivity. However, it has physical characteristics that present technical difficulties—most notably, its tendency to cake during storage. This caking compromises the dosing and injection process, reducing overall system performance.
A major global player in the design and construction of flue gas treatment systems faced a challenge involving the treatment of extremely high volumes of acid gases emitted by a large waste-to-energy facility, which required up to 2 tons of bicarbonate injection per hour.
The key technical requirements included:
– Achieving a particle size of less than 35 µm for optimal chemical reaction.
– Preventing caking and blockages during sorbent storage.
– Ensuring continuous and controlled injection to maximise removal efficiency.
– Providing a compact and easy-to-integrate system within the existing plant layout to minimise engineering and installation time.
The Solution: Bicarmill® 800 by STM Microtec
To meet these requirements, STM Microtec supplied two Bicarmill® 800 units. This plug-and-play solution combines real-time grinding and direct injection of sodium bicarbonate into a single compact system. Unlike pre-ground bicarbonate, which is prone to caking, the Bicarmill® mills the sorbent only at the time of use, ensuring optimal flowability, consistent particle size, and high reactivity.
Technical and Operational Benefits:
– Maximum Reaction Efficiency: By grinding bicarbonate to less than 35 µm, the system increases the available surface area for chemical reactions. This reduces the stoichiometric ratio and improves overall removal efficiency. – No Caking or Blockage Risks: real-time grinding eliminates storage-related issues, enhancing system reliability and ensuring uninterrupted dosing.
– Compact, Integrated System: The Bicarmill® 800 is easy to install due to its modular design and silent-block mounting, with no need for floor anchoring.
– Smart Monitoring and Easy Maintenance: Each unit features automated lubrication, vibration and temperature sensors, an anti-caking dosing system, and remote diagnostics for predictive maintenance and process optimisation.
Conclusion
The implementation of the Bicarmill® 800 by STM Microtec proved to be a strategic, high-performance solution for the customer. It boosted the reactivity of the sorbent, enhanced acid gas removal efficiency, and ensured compliance with stringent emission regulations. This case demonstrates how advanced engineering, process efficiency, and ease of integration can effectively address complex challenges in the air pollution control industry.
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