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Current U.S. Air Pollution Control Technologies


And Future Trends

William J. Morris
Manager, Particulate Systems
Hamon Research-Cottrell, Inc.
Somerville, New Jersey, USA

July 2002

The North American air pollution control market continues to evolve in response
to new and changing environmental regulations, new technologies, and even some new
applications of proven technologies. Some of the future changes expected in the
environmental regulations include tighter emissions regulations on SO2, NOx, PM-2.5,
Mercury control and air toxics such as lead, and cadmium.
As regulations change and markets react, Hamon Research-Cottrell, Inc. (HR-C)
is also continually refining and upgrading product offerings. HR-C has been very
successful in the North American market in the past two (2) years with numerous
contracts for DeNOx Selective Catalytic Reduction (SCR), pulse jet fabric filters and
rigid discharge electrode ESPs. To provide a more complete product line of air pollution
control technologies, and to address this changing marketplace, HR-C has recently
included an additional type of lime spray dryer absorber for Dry Flue Gas
Desulfurization (DFGD), new Wet Electrostatic Precipitator (WESP) technologies and
single tower Insitu Forced Oxidation Wet Flue Gas Desulfurization (IFO-WFGD)
systems. We have accomplished this expansion through a series of acquisitions, joint
venture partnerships, licenses and new applications of existing technologies.

Current US EPA environmental regulations

U.S regulations can be found in different forms. In 1970, the U.S. Environmental
Protection Agency (EPA) began regulating “criteria air pollutants” with the passage of
the Clean Air Act (CAA). Criteria air pollutants are those that can injure health, harm the
environment and cause property damage. In 1990, the CAA was revised to reduce acid
air pollutants, considered to be connected to “acid rain”. Part of the regulations that
resulted includes a New Source Review (NSR). In a very controversial move, the
USEPA is now targeting utilities that did upgrades on their plants during the last 10
years without installing additional air pollution control (APC).

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The US air pollution regulations are complicated and very specific to industries
and applications. Below are some current general guidelines for each of the major air
pollutants.

SO2 Emissions – The U.S CAA, Title IV, 1990, required utilities to achieve SO2
emission levels of 520 ng/J (1.2 lb /million BTU) by 2000. The U.S. utilities had
several options:
• Switch to lower sulfur fuels
• Blend current coal with lower sulfur fuel
• Install FGD systems
• Purchase or trade SO2 allowances –currently trading at $ 172 US.

Switching and blending fuels was the main strategy of 62 % (162 of 261) of the
affected units.

Particulate Emissions – The U.S CAA, Title IV, 1990, as identified in code of
Federal Regulations 40 CFR 60.42, also required utilities to achieve particulate
emission levels of 13 ng/J (0.015 lb/million BTU) by 2000. The U.S. utilities had
several options here also:
• Switch to lower ash fuels
• Blend current coal with lower ash fuel
• Install or upgrade particulate control systems
• Derate or retire units.

In response, many particulate systems were upgraded and older units were
retired.
In 1997, additional changes were made to the CAA to revise air quality
standards for ground level ozone (smog) and fine particulate matter (haze). The
new standards for particulate were for particulate matter less than 2.5 micron
(PM-2.5). These were 15 µg/m3 and 65 µg/m3 for annual and 24 hour standards.
These size specific particulate matter standards are now being observed in the
specifications for new air pollution control equipment.

NOx Emissions – The U.S CAA, Title IV, 1990, required utilities to achieve NOx
emission rates of between 86 and 340 ng/J (0.20 to 0.75 lb /million BTU) by
2000. The U.S. utilities again had several options:
• Combustion modifications
• Low NOx burners
• Install SCR or SNCR systems
• Purchase or trade NOx allowances –recent averages are $ 4,660
US (2002) and $ 4,800 US (2003).

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Current and Future Air Pollution Control Markets

The North American air pollution control market (essentially the U.S and Canada)
continues to evolve in response to these new and changing environmental regulations,
new technologies, and new applications of proven technologies. Some of the future
changes expected in the environmental regulations include additional restrictions on
PM-2.5, mercury emissions and air toxics such as lead. Below are shown some industry
projections of the current and future market for various air pollution control technologies.

- Electrostatic Precipitators

The projected total ESP market for 2002 through 2004 is shown in Table 1.

2002 2003 2004


Power Generation 55.3 60.4 66.2
Pulp and Paper 17.3 22.5 24.0
Other 31.4 34.6 37.6
Total, Flange to Flange 104.0 117.5 127.8
Aftermarket and Erection 150.6 159.3 167.0
Totals 254.6 276.8 294.8

Table 1
ESP Market Breakdown ($ millions U.S)

Source: ICAC Market Forecast, reference 1

Of this total 51 to 53 % of the flange to flange total is in the power generation


industry. One market driver in the power generation market will be higher natural gas
prices. Wet ESPs will grow in demand as a means of capturing sulfuric acid aerosols
from burning higher sulfur fuels (like pet coke) and from SCR installations where SO2
gets catalyzed to SO3 and subsequently forms H2SO4 acid. Wet ESPs also show some
promise as an enhancement for improved fine particle control.

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- Fabric Filters

The projected total Fabric Filter (FF) market for 2002 through 2004 is shown in
Table 2.

2002 2003 2004


Power Generation 31.3 36.4 42.8
Rock Products 18.0 18.8 19.9
Other 94.3 97.5 101.8
Total, Flange to Flange 143.6 152.7 164.5
Aftermarket and Erection 165.0 172.8 181.8
Totals 308.6 325.5 346.3

Table 2
FF Market Breakdown ($ millions U.S)

Source: ICAC Market Forecast, reference 1

While many power producers are concentrating on SCR for NOx reductions, the
California energy situation in 2001 also has produced a renewed interest in new coal
fired plants. However, PM-2.5 and Hg control will probably not create new opportunities
until 2004. The aftermarket, including bag replacements and parts, is expected to be 41
to 42 % of the FF market through 2004. Increased use of pleated filter bags is expected
since more filter area can be put in smaller casings. The use of membrane type filter
media is also expected to increase as an enhancement for improved fine particle
control.

- Wet Scrubbers

The projected total Wet scrubber (WS) market for 2002 through 2004 is shown in
Table 3.

2002 2003 2004


Chemical 14.2 14.6 15.2
Incineration 11.3 12.1 13.3
Other 60.4 63.4 66.7
Total, Flange to Flange 85.9 90.1 95.2
Aftermarket and Erection 21.5 22.5 23.8
Totals 107.4 112.6 119.0

Table 3
WS Market Breakdown ($ millions U.S)

Source: ICAC Market Forecast, reference 1

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Slow market recovery is expected after the U.S. recession ends. As the
industries gain strength and Maximum Achievable Control Technology (MACT)
standards start to take hold, the market is expected to expand. In the incineration
market WS, may be favored over WESPs due to ability to operate at higher velocities.

- NOx Control

NOx Control (or DeNOx) is currently the dominant market in the U.S. air pollution
control industry. This situation is expected to continue through 2010. Several
regulations are providing the impetus for NOx controls. These include SIP, NSR, and Air
Toxics, as well as NAAQS, and Regional Haze regulations. The projected total NOx
control market for 2002 through 2004 is shown in Table 4.

DeNOx type 2002 2003 2004


SCR 2,222.5 2,080.3 1,374.1
SNCR (inc. gas reburn) 124.3 145.7 133.2
NSCR 11.0 12.2 13.5
LNB/other 160.5 172.2 182.5
NOx Total 2,518.3 2,410.4 1,703.3

Table 4
Total NOx Market Breakdown by Product ($ millions U.S)

Source: ICAC Market Forecast, reference 1

SCRs for NOx control are currently the dominant product for DeNOx in the U.S.
air pollution control industry. SCRs will account for 80 to 90 % of the NOx market at
least through 2004. However, SNCR is expected to show the greatest growth over the
next few years, especially in the power generation segment. This situation is expected
to continue through 2010.

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The projected total NOx control market by end user for 2002 through 2004 is
shown in Table 5.

End-User 2002 2003 2004


Power Generation 1,871.7 1,750.42 1,107.8
Gas Turbines 322.5 277.0 274.8
Refinery 176.8 212.0 129.8
Ind. Boilers 76.8 82.5 90.8
IC Engines 61.0 77.5 87.6
MSW Incineration 2.0 2.0 2.0
Other 7.5 9.0 10.5
NOx Total 2,518.3 2,410.4 1,703.3

Table 5
Total NOx Market Breakdown by End-Use ($ millions U.S)

Source: ICAC Market Forecast, reference 1

Power generation utility boilers will account for 75-87 % of the SCR end user
market at least through 2004. Energy shortages, high natural gas prices and the Bush
administration’s current initiatives are driving resurgence in coal. As of 2002, over 40
new coal fired plants have been announced. Energy shortages are also leading to
increased activity in gas turbines where 15-18 GW have been forecast per year through
2004.

- Flue Gas Desulfurization

The FGD market can be easily divided into two (2) primary technologies, Wet
FGD and Dry FGD. The Total FGD market includes both Wet and Dry Flue Gas
Desulfurization systems. The projected total FGD market for 2002 through 2004 is
shown in Table 6-1.

2002 2003 2004


Utility 457.5 555.0 630.0
Industrial and MSW 44.5 75.6 121.7
Totals 502.0 630.6 751.7

Table 6-1
Total FGD Market Breakdown ($ millions U.S)

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The wet vs. dry split of the Electric Utility FGD market for 2002 through 2004 is
shown in Table 6-2.

2002 2003 2004


Wet (MW) 1,800 4,500 5,520
Dry (MW) 3,850 1,500 1,500

Wet (% of MW) 31.9 75.0 78.1


Dry (% of MW) 68.1 25.0 21.9

Table 6-2
Electric Utility FGD Orders ($ millions U.S)

Only 33 % of U.S. Utility plants have installed scrubbers. The first big wave in the
U.S. air pollution control market is for SCRs for DeNOx. The second wave will be
increases in FGD expenditures for SO2 control. Some of this is driven by the New
Source Review (NSR) standards currently being debated in Washington, D.C. Between
2002 and 2004, a mix of new units, retrofits and NSR required projects are expected. By
2004, a 39 % increase in the Utility market is expected over 2001 levels.

The wet vs. dry split of the Industrial and MSW markets for 2002 through 2004 is
shown in Table 6-3.

2002 2003 2004


Industrial 36.5 67.1 112.7
MSW 8.0 8.5 9.0

Wet ($ MM) 16.4 44.8 87.2


Dry ($ MM) 28.1 30.8 34.5
Total 44.5 75.6 121.7

Wet (% of $ MM) 36.9 59.3 71.7


Dry (% of $ MM) 63.1 40.7 28.3

Table 6-3
Industrial & MSW Orders ($ millions U.S)

Source: ICAC Market Forecast, reference 1

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The Industrial FGD market is expected to post strong increases after 2002,
especially in the petroleum refinery area, which has a big potential for increase from
2002 to 2004. This is partly due to rising refinery profitability and partly due again to
NSR.
It is expected that Wet FGD will capture the majority of the total FGD market from
2002 to 2004 due to an expected surge in Utility and refinery retrofits. Dry FGD will still
be used in some new Utility and CFB boiler projects. Even though a limestone injected
fluid bed boiler could remove up to 80 % of the SOx in the flue gas, current regulations
typically require a dry FGD system to remove 90 % of the remaining SO2. A Dry FGD
system is also very effective at removing excess SO3 and H2SO4, which may be
generated by installation of an SCR for NOx control.

Future Emissions Controls Expectations

- SO2 emissions – As demonstrated in the revised 1990 CAA, sulfur dioxide


emissions will continue to tighten. Since atmospheric SO2 is a considered a precursor
chemical and may be one component of atmospheric visibility problems and “acid rain”,
there will continue to be an emphasis on reducing SO2 emissions. State Implementation
Plans (SIPs) will also continue to target source reductions.

- NOx reductions – NOx emissions will also continue to tighten. Since


atmospheric NOx is also considered a precursor chemical to ozone formation and may
also be one component of atmospheric visibility problems and “acid rain”, there will
continue to be an emphasis on reducing NOx emissions. These reductions will include
SCR’s and SNCR’s on previously unregulated sources such as utility gas turbines.

- PM-2.5 – During the last several years, this pending legislation has withstood
several judicial reviews. Epidemiological studies have also confirmed the health impacts
of PM-2.5. This issue really relates to ambient air quality. Stack emissions are only one
source of atmospheric concentrations of PM-2.5. Other sources are road dust,
automobile exhausts and acid condensation in the atmosphere. To reduce ambient
levels requires reductions in precursor chemicals such as SO2 and NOx as well as
primary particulates. Studies in the Eastern US have shown that as much as 50 % of
PM-2.5 actually consists of condensable sulfates, nitrates and ammonium.
The U.S. air pollution control industry will probably not see source specific
regulations for PM-2.5 until 2004-2005.

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- Mercury – Clean Air Act, section 112, requires power plant reductions by 2007.
EPA Rules are currently being developed. Presently the high number of US lakes that
have fish consumption advisories due to mercury deposition will continue to put
regulatory pressure on this pollutant. If EPA does not act, then a hodgepodge of state
rules will emerge which will be difficult for companies with interstate operations. (Ref. 2)
A recent report (Ref.3) indicates that carbon injection is the most mature retrofit
technology available for mercury reductions. Full scale tests with carbon injection have
demonstrated 50-70 % mercury reductions on units with ESPs and as much as 90 % on
units with fabric filters for final particulate cleanup.

- Multi-pollutant Technologies - The benefits in combining several technologies


together for multi-pollutant control are obvious. Typically, the multi-pollutants combined
are SOx, NOx and particulate control. A DFGD and fabric filter system has multi-
pollutant control ability in that the combination controls SO2, SO3, and particulate
emissions. The particulate captured often includes heavy metals such as lead, cadmium
and zinc, as well as other toxic materials such as arsenic.
Recently, HR-C has also been involved in several successful efforts to combine a
high ratio pulse jet fabric filter downstream of an ESP. This EPRI patented system is
referred to as a COHPAC (COmpact Hybrid PArticulate Collector) unit. When combined
with carbon injection systems these systems have provided both high efficiency
particulate control as well as mercury removal in the 50 to 90 % range.

- President Bush’s Clear Skies Initiative - In advancing the multi-pollutant


concept, U.S. President Bush introduced the “Clear Skies Initiative” on Feb 14, 2002.
This Presidential action will further reduce power plant emissions of nitrogen oxides,
sulfur dioxide, and mercury. Specifically, the cuts would include:

• Reductions in SO2 by 73 % from current levels to 3 million tons/year in


2018.
• Cut emissions of NOx by 67 % from current levels to 1.7 million tons in
2018.
• Implement the first ever national cap on mercury emissions, cutting from
current levels to a total of 15 tons/year in 2018, a 69% reduction.

The initiative also includes a strategy for reducing greenhouse gas intensity by
18 % over the next ten years. Greenhouse gas intensity is the ratio of greenhouse gas
emissions to economic output. This goal is comparable to the average progress
required by the Kyoto Protocol.

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Air Pollution Control Equipment Trends –

As the air pollution control equipment market changes, so do the product


offerings of the various vendors in response to the market, but also in response to new
technologies, positive experiences with previously unproven systems and customer
expectations. An example would be the widespread use of wide plate spacing (400 mm)
and rigid discharge electrodes in ESPs where at one time narrower spacing (230 mm)
and weighted wires were the norm. Another example is the present use of large pulse
jet fabric filters with long (7-8 meter) bags for applications where 5-10 years ago, only
reverse gas fabric filters would have been considered. Of course economics always
play a part in driving the technology toward the most cost effective, proven design.

Some of the trends we have observed are indicated below.

Fabric filters – After over 50 years of use, fabric filters continue to evolve:
Reverse gas to Pulse jets
Short (3.7 to 4.9 m) to long (5.5 to 8 m) bags
Heavy synthetic felt 18 oz and composites
Self-supporting synthetic felts (higher burst pressure, lower shrinkage rates)
No bypass or limited bypass (temperature only)
Operation with Oil firing required

ESPs – These products are fairly mature. Current design trends would be:
Rigid discharge electrodes
Wide plate spacing – 400 mm typical
Variable plate spacing within unit
Larger and fewer Transformer-Rectifier sets

WFGD – Also a mature product but with some very recent enhancements:
Single tower IFO limestone systems.
Internal modifications (rings and shelves) for enhancement of L/G rates
WESPs or NH3 injection for H2SO4 mist elimination.

DFGD – A more recent technology but growing in popularity.


Dry injection with Humidification or 2 fluid nozzles for acid gas systems
Semi-dry with atomizers for larger SO2 control systems
Large (up to 15 meter diameter) absorber vessels
12 to 15 seconds residence time to insure dry product
Carbon addition for mercury control

DeNOx – still a relatively recent APC technology. Industry is always searching for
an alternative to NH3 reagent.
Urea for generating ammonia gas
WESPs for SO3 control

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Hamon Research-Cottrell (HR-C) product offerings

Hamon Research-Cottrell, Inc. (HR-C) is continually upgrading product offerings


to address this ever changing market place. We have accomplished this expansion
through a series of acquisitions, joint venture partnerships, licenses and new
applications of existing technologies. These have expanded to keep pace with the
market changes.
For example, HR-C has recently added Wet Electrostatic Precipitator (WESP),
lime spray dryer absorbers for Dry Flue Gas Desulfurization (DFGD), and single tower
Insitu Forced Oxidation Wet Flue Gas Desulfurization (IFO-WFGD) systems to provide
a complete product line of air pollution control technologies.

Hamon Research-Cottrell’s Technologies

HR-C is a full spectrum supplier of air pollution control equipment for both utility
and industrial markets. In addition, HR-C coordinates product designs and activities with
over 40 Hamon offices throughout the world. Many of these Hamon offices market air
pollution control products that have obtained local acceptance and address local
markets. At HR-C-US, we also try to provide air pollution control products, which
address our North American market. Listed below are our current products, several
recent activities and a summary of new products, which indicate the breath of our
efforts.

Air pollutant HR-C’s Product recommendations

Sulfur Dioxide, SO2 WFGD, DFGD, DI

Sulfur Trioxide, SO3 DFGD, DI, WESP

Oxides of Nitrogen, NOx SCR, SNCR, Urea to Ammonia (U2A)

Particulates Reverse Air and Pulse Jet fabric filters, Rigid


Discharge Electrode ESPs, WESPs, COHPAC
systems

PM-10, PM-2.5 Reverse Air and Pulse Jet fabric filters,


WESPs, COHPAC systems

Air toxics Reverse Air and Pulse Jet fabric filters,


WESPs, COHPAC systems

Mercury Carbon Injection upstream of Reverse Air and


Pulse Jet fabric filters, COHPAC systems

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HR-C Recent activities and acquisitions –

Turbosonic – in 2001, HR-C has purchased an equity interest in Turbosonic. This


company provides industrial wet scrubbers and WESP technology. A joint
marketing and proposal effort is ongoing.

Entech – also in 2001, HR-C purchased the assets of Entech, an ESP and
WESP supplier with construction group.

Marsulex Environmental Technologies (MET) – in early 2002, HR-C purchased


all particulate product lines including ESPs and fabric filters and
associated personnel from MET and also obtained an exclusive North
American license for MET DFGD and Wet Limestone FGD product lines.

New Product Summary –

UtoA – This technology is a joint venture with Walhco, Inc. to market and install
urea to ammonia systems as an alternative to inherently dangerous anhydrous
ammonia gas systems. Already used successfully at several SCR installation
sites. UtoA (or U2A) stands for Urea to Ammonia Conversion. UtoA is used as a
safer alternative for an Ammonia source for DeNOx products. UtoA is actually a
chemical process called hydrolyzation, creating ammonia from an aqueous
solution of urea under the presence of a heat source. The first commercial
operation was in July 2001 at Huntington Beach, California for AES. In
September 2001, HR-C completed successful testing of 2000 lb/hr unit at
Harrison Station in West Virginia for Allegheny Power.

U2A: HR-C & Wahlco Projects

• AES/Huntington Beach Station, Units 1,2,3,4


• Allegheny Energy Supply/Harrison, Units 1,2,3
• Allegheny Energy Supply /Pleasants, Units 1,2
• DTE Energy /Monroe Station, Units 1,2,3, & 4
• Constellation Power Source Generation/Wagner, Unit 3
• Innovative Steam Technology for Kauai Power Partners, Hawaii

It should be noted that the above projects account for over 7300 MW of NOx
control and 16,740 lb/hr of ammonia supplied.

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COHPAC – EPRI licensed technology to utilize high ratio fabric filters


downstream of installed ESP, as a final polishing device providing enhanced
particulate removal.

COHPAC, HR-C Jobs

• Texas Utilities-Big Brown Unit 1 and 2


• Alabama Power Gaston Unit 2 and 3
• SEMASS unit 1 and 2

SCR - HR-C has been very successful in the North American market in the past
two (2) years with numerous contracts for Selective Catalytic Reduction (SCR)
systems for NOx control on combustion units. A summary of recent projects is
shown below.

SCR and SNCR Projects

• 2 Utility Coal Fired Boilers


• 18 HRSG’s
o 16 Horizontal Flow
o 2 Vertical Flow
• 36 Open Cycle Gas Turbines
o 6 WH501FD’s
o 3 GE Frame 7’s
o 16 LM6000’s
o 7 LM2500’s
o 2 Solar Turbines

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Summary

It sometimes seems that the constant evolution of proposed and


promulgated regulations and ever-lower emissions requirements will never end.
That may be one of those facts of life. As our technologies improve, we are
expected to do more to protect our environment.
Our customers certainly have a difficult job picking air pollution control
technologies, which could require upgrade and/or retrofit after only a few years of
operation to meet a new and even more difficult requirement. After 2004, the
U.S. market will be looking at the additional effects of regulations for PM-2.5, and
mercury. The impact of the “Clear Skies Initiative” to reduce SO2, NOx and also
mercury to specific targets by 2018 will also be observed in the next ten years, as
air pollution control equipment evolves toward multi-pollutant capabilities.

The Hamon Research-Cottrell Company along with other Hamon Group


companies throughout the world is constantly striving to provide the most cost
effective solutions to the ever-changing air pollution control markets. Our stated
goal is to establish a culture of quality within Hamon that will enable us to
become “The Best Environmental Equipment Supplier in the World”.
In North America, we believe we are achieving this through an evolution of
products that has occurred as a result of joint ventures and equity partnerships,
strategic technology licenses, proprietary new products and acquisitions. As the
market continues to respond to changing regulations, Hamon Research-Cottrell
will continue to look for the most cost effective means of assisting our customers
with these challenges.

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58, East Main Street Tel: 908-333-2006 Tel: 1-800-722-7580 or 908-333-2154
Somerville, NJ 08876 Fax: 908-333-2165 Fax: 908-333-2154
 HAMON. All rights reserved U.S.A. info.hrcus@hamonusa.com parts.hrcus@hamonusa.com
www.hamonusa.com

References
BACK

1. - Air Pollution Control Equipment Market Forecasts, Issue No. 20,


September 2001, ICAC-Institute of Clean Air Companies

2. - Personal correspondence from ICAC’s, Jeffery C. Smith, to U.S.


Senator Jim Jeffords, chairman, Committee on Environment and
Public Works. December 7, 2001.

3. - National Coal Council report, May 2002

4. - U.S. Environmental Protection Agency, May 2002.


URL:http://epa.gov/clearskies/

Abbreviations

HR-C Hamon Research-Cottrell


APC Air Pollution Control
SCR Selective Catalytic Reduction
SNCR Selective Non-Catalytic Reduction
UtoA, U2A Urea to Ammonia
ESP ElectroStatic Precipitator
WESP Wet ElectroStatic Precipitator
FGD Flue Gas Desulfurization
DFGD Dry Flue Gas Desulfurization
WFGD Wet Flue Gas Desulfurization
IFO Insitu Forced Oxidation
DI Dry Injection
FF Fabric Filter
PJFF Pulse Jet Fabric Filter
COHPAC COmpact Hybrid PArticulate Collector
HRSG Heat Recovery Steam Generator
ICAC Institute of Clean Air Companies
EPA Environmental Protection Agency
CAA Clean Air Act
NSR New Source Review
SIP State Implementation Plan
NAAQS National Ambient Air Quality Standards

Hamon Research-Cottrell New Products Parts and Customer Service 15


58, East Main Street Tel: 908-333-2006 Tel: 1-800-722-7580 or 908-333-2154
Somerville, NJ 08876 Fax: 908-333-2165 Fax: 908-333-2154
 HAMON. All rights reserved U.S.A. info.hrcus@hamonusa.com parts.hrcus@hamonusa.com

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