Our experienced engineers have custom-designed emission control systems for a broad spectrum of process heater designs and capacities. One of the issues with the use of industrial fired heating systems is the amount of nitrogen oxides or NOx and other pollutants these operations release into the atmosphere. It is important that emission levels are below federal and local mandates.
We offer a wide range of pre- and post-combustion options for reducing emissions and we know how to maximize the contribution of each technology without sacrificing unit performance.
We can analyze each system to estimate NOx reduction potential; taking into account existing equipment design, current levels of NOx emissions, space and budget constraints and potential downtime. Saratoga Energy Resources can provide process and emission guarantees on every emissions control project we manage.
Emission Control Options
Low NOx Burners
The most common method and often the first step to control emissions is to install a Low or Ultra-low NOx Burner. These burners control the mix of fuel and air to lower flame temperature and reduce oxygen concentration which results in lower NOx production. We custom-design each unit to maximize NOx reduction without sacrificing combustion performance or unit operation.
- Cost-effective way to reduce emissions by 40-60%
- Simplest NOx-control technology option to install
- Will not increase operating costs or decrease efficiency
- Reduce NOx emissions without a corresponding increase in CO emissions
Flue Gas Recirculation (FGR)
FGR units recirculate external flue gas into the combustion air stream which lowers the peak flame temperature and cuts thermal NOx formation. The addition of flue gas also reduces the oxygen available to react with the nitrogen. FGR can cut NOx emissions on conventional burners by 50-70% and can also be used in conjunction with Low NOx burners.
Selective Catalytic Reduction
Selective Catalytic Reduction (SCR) units provide an effective and affordable solution to NOx emissions restrictions for industrial furnace applications. Selective Catalytic Reduction is a post-combustion NOx control option that uses a chemical reaction to separate the NOx into harmless nitrogen and water, thereby reducing overall NOx emissions.
Saratoga Energy Resources can design or retrofit your fired heating system with a highly integrated and optimized SCR unit. Our thorough understanding of fired heating applications allows us to maximize SCR performance while minimizing its impact on plant operations.
- Custom designed for site-specific conditions
- Flexibility and features to support day-to-day operations
- NOx reductions as high as 90 percent are possible
- Low running and maintenance cost
- Excellent reliability
Our Waste Heat Recovery Units, Air Preheat Systems and other Revamps and Upgrades are designed to reduce fuel consumption and increase system efficiency which in turn reduces the amount of pollutants your fired heating system emits.