Revolutionizing Flue Gas Treatment with Advanced High-Temperature Ceramic Membrane Filtration

In the demanding landscape of industrial emissions control, achieving consistent ultra-low emissions standards presents significant technological challenges. Traditional sequential treatment systems—combining SCR/SNCR denitrification, baghouse or electrostatic precipitators for dust removal, and separate desulfurization units—often struggle with space constraints, high operational costs, and sensitivity to complex flue gas compositions containing alkalis, heavy metals, and sticky particulates. High-temperature ceramic membrane filtration, as developed and perfected by ZTW Tech, emerges as a transformative integrated solution that consolidates multiple pollution control functions into a single, robust, and highly efficient system.

The Technological Foundation: ZTW Tech's Proprietary Ceramic Filter Elements

At the heart of ZTW Tech's system are two core, company-developed components:

• Ceramic Catalytic Filter Tubes/Cartridges: These elements are engineered with integrated nano-catalytic coatings within a porous, high-strength ceramic matrix. They perform simultaneous deep filtration of particulate matter (down to sub-micron and nano levels) and catalytic reduction of NOx (DeNOx) at temperatures typically between 300°C and 450°C. This eliminates the need for a separate, upstream SCR reactor and its associated ammonia injection grid, simplifying the plant layout and reducing ammonia slip concerns.
• High-Temperature Ceramic Fiber Filter Tubes/Cartridges (Non-Catalytic): Designed for applications where only high-efficiency filtration at elevated temperatures is required, or where the gas composition is unsuitable for catalytic elements. These filters exhibit exceptional resistance to thermal shock, chemical corrosion from acidic components (SO2, HCl, HF), and physical abrasion.

Both types of elements leverage a nanoscale pore structure, which ensures >99.9% filtration efficiency for fine dust and aerosols. Their inherent characteristics—high gas-to-cloth ratio, low pressure drop, and mechanical strength—allow for more compact system designs compared to baghouses and provide a service life exceeding five years, even in harsh conditions where alkaline (e.g., Na, K) and heavy metal (e.g., As, Pb) concentrations would rapidly deactivate conventional SCR catalysts or degrade fabric filter bags.

Integrated Multi-Pollutant Abatement: How the System Works

ZTW Tech's Ceramic Integrated Multi-Pollutant Ultra-Low Emission Flue Gas Treatment System is not merely a filter; it is a complete process engineered around the high-temperature ceramic membrane filtration core. The process flow typically involves:

1. Flue Gas Conditioning & Reagent Injection: Hot flue gas from the industrial kiln is conditioned to the optimal temperature window. If needed, a powdered sorbent (e.g., hydrated lime, sodium bicarbonate) for acid gas removal and a reducing agent (e.g., ammonia) for NOx reduction are injected upstream of the ceramic filter vessel.
2. Filtration & Reaction Zone: The gas enters the vessel containing multiple modules of ZTW Tech's ceramic filter elements. As the gas passes through the porous walls of the tubes:
   • Dust, unburned carbon, and heavy metal aerosols are trapped on the surface or within the pore structure.
   • NOx molecules contact the integrated catalyst in catalytic elements and are reduced to N2 and H2O.
   • Acidic gases (SO2, SO3, HCl, HF) react with the sorbent trapped in the dust cake on the filter surface, forming solid salts.
   • Dioxins and Furans are adsorbed onto the dust cake and/or destroyed catalytically on specific catalyst formulations.
3. Cleaning & Waste Disposal: The accumulated dust cake is periodically removed by short, powerful pulses of compressed air. The solid waste, containing reacted sorbents and captured fly ash, is collected in a hopper for disposal. This pulsed cleaning maintains a stable, low pressure drop.

This single-step, in-filtration reaction mechanism is key to the system's efficiency and compactness. It overcomes the classic bottleneck where high dust loads poison downstream SCR catalysts. Here, dust is removed before it can interfere with the catalytic reaction, as the reaction occurs directly on the dust-free side of the filter wall or within the catalyst-integrated wall itself.

Application-Specific Advantages Across Key Industries

ZTW Tech's solutions are not one-size-fits-all. The high-temperature ceramic membrane filtration system is tailored to address the unique challenges of various sectors:

• Glass Melting Furnaces: These kilns emit flue gas with high concentrations of alkali vapors (sodium), borates, and fine particulate. Traditional SCR catalysts are highly susceptible to alkali poisoning. ZTW Tech's ceramic catalytic filters, with their dust-removal-first design, prevent alkali condensation on the active sites, ensuring sustained DeNOx efficiency and long catalyst life, achieving NOx levels well below 200 mg/Nm³.
• Biomass & Waste-to-Energy Boilers: Flue gas from burning biomass or municipal solid waste is highly challenging, containing sticky alkali salt aerosols, heavy metals (e.g., mercury, cadmium), and varying levels of HCl, HF, and SO2. The system's ability to handle sticky dust through careful temperature control, combined with simultaneous acid gas removal and filtration, makes it an ideal solution. It effectively controls dioxin emissions through combined filtration and catalytic destruction.
• Steel Industry & Sintering Plants: Emissions are characterized by high dust loads, often with iron and zinc oxides, and fluctuating gas conditions. The mechanical robustness and high-temperature tolerance of the ceramic elements ensure reliable performance. The integrated DeNOx function helps meet stringent NOx standards without the space requirements of a separate SCR unit.
• High-Fluorine Industries (e.g., Aluminum Smelting, Phosphoric Acid Production): HF is highly corrosive and challenging to remove. The system's use of appropriate sorbents (e.g., alumina) in conjunction with the ceramic filter achieves high HF removal rates, protecting downstream equipment and meeting strict emission limits.
• Cement Kilns & Lime Kilns: While often equipped with efficient particulate control, these industries face tightening NOx limits. Retrofitting with a ZTW Tech ceramic catalytic filter system downstream of the preheater can be a more compact and efficient alternative to installing a separate SCR system, especially when alkali bypass dust is an issue.

Comparative Benefits vs. Conventional Technologies

Choosing ZTW Tech's high-temperature ceramic membrane filtration system over a cascade of traditional technologies offers compelling operational and economic advantages:

The ZTW Tech Advantage: Engineering for Long-Term Reliability

Beyond the core technology, ZTW Tech's value lies in its holistic engineering approach. Each system is designed with:

• Advanced Module & Vessel Design: Ensuring even gas distribution, efficient cleaning, and easy access for minimal maintenance.
• Intelligent Control Systems: Automating pulse cleaning cycles based on differential pressure, optimizing reagent injection rates, and providing real-time performance monitoring.
• Comprehensive Support: From initial flue gas analysis and pilot testing to installation supervision, commissioning, and lifecycle service support, including filter element replacement programs.

For plant managers and environmental engineers seeking a future-proof solution to meet and sustain the most stringent global emission standards (e.g., China's Ultra-Low Emissions, EU BREF standards), the integrated approach centered on high-temperature ceramic membrane filtration represents a significant technological leap. It transforms emission control from a series of vulnerable, high-maintenance processes into a consolidated, robust, and cost-effective asset.

ZTW Tech stands at the forefront of this technology, with proven references across continents. By addressing the core challenges of catalyst poisoning, system complexity, and waste handling, our systems deliver not just compliance, but operational simplicity and long-term investment protection. Contact our engineering team to discuss how a customized ceramic integrated multi-pollutant control system can solve your specific flue gas treatment challenges.