Tail Gas Recovery Purification and Dehydration Solution

Industry Pain Points

  • High Humidity Corroding Equipment: The moisture content in exhaust gas is saturated (dew point ≥ 60℃), which combines with SOx/NOx to form acidic condensate. This causes corrosion and perforation of pipelines and fans, increasing maintenance costs by 40%.
  • Low VOCs Recovery Efficiency: Traditional condensation methods lose 30-50% of organic components (such as benzene series and alcohols) while dehydrating. The annual resource waste exceeds 5 million RMB (based on 100,000 Nm³/h).
  • Conflict Between Energy Consumption and Environmental Protection: Deep dehydration requires 0.2-0.4 kWh/Nm³ of electricity, yet carbon reduction policies mandate an annual 5% reduction in process energy consumption.
  • Interference from Complex Components: Exhaust gas contains dust (50-200 mg/m³), oil mist (1-10 ppm), hydrogen sulfide, etc. Conventional adsorbents fail within 3 months.

SYSTEM OVERVIEW

Yipu Exhaust Gas Purification and Dehydration System adopts the technology chain of “cyclonic dust removal – cascade condensation – thermal regeneration adsorption” to achieve:

  • Corrosion Prevention and Control: Acidic condensate is reduced by 90%, extending equipment service life by 3 times.
  • Dual Benefits: VOCs resource utilization + water conservation and emission reduction, with an investment payback period of <1.5 years.
  • Intelligent Operation: A digital twin model predicts pipeline scaling trends, reducing maintenance costs by 60%.

Technology Evolution

  • Launched a CO₂ co-capture version in 2024, enabling carbon emission reduction while dehydrating.
  • Developed a mobile container solution to handle emergency pollution incidents.
  • This solution is a key technical equipment for process industries to achieve ultra-low emissions and circular economy.

Solution Approach

Yipu Exhaust Gas Recovery, Purification and Dehydration Solution

ModuleTechnical HighlightsPerformance Parameters
Cyclonic Purification TowerSilicon carbide lining + ultrasonic anti-cloggingDust ≤ 1 mg/m³, oil mist ≤ 0.1 ppm
Cascade CondenserR404A/R23 cascade refrigeration, COP ≥ 3.5Dew point -25℃, VOCs recovery rate ≥ 80%
Acid-Resistant Adsorption Tower316L base + PTFE-coated molecular sieveOutlet dew point -40℃, H₂S resistance ≤ 3000 ppm
Heat Pipe Regeneration SystemExhaust gas waste heat recovery rate ≥ 90%Regeneration energy consumption ≤ 0.03 kWh/Nm³
Intelligent ControlGC-MS online analysis + AI dynamic optimization of condensation temperatureVOCs recovery purity ≥ 95%

Applicable Scenarios

  • Catalytic cracking exhaust gas in the petrochemical industry
  • Fermentation waste gas from pharmaceutical enterprises
  • Organic waste gas from coating production lines
  • Flue gas treatment in waste incineration plants

Technical Principles

Yipu Four-Stage Synergistic Purification Process

  1. Turbulent Dust and Oil Removal (Stage 1): The high-gravity cyclone removes 98% of particles and 90% of oil mist within 0.3 seconds (pressure loss ≤ 500 Pa).
  2. Cascade Condensation (Stage 2): The cascade refrigeration system (+5℃ → -25℃) performs segmented condensation, recovering 60% of moisture and 80% of high-boiling-point VOCs.
  3. Anti-Fouling Adsorption (Stage 3): Hydrophobic molecular sieves (Type 3A-TG) maintain a dew point of -40℃ in a pH 2-12 environment, with a sulfur poisoning resistance life of 5 years.
  4. Waste Heat Regeneration (Stage 4): Uses exhaust gas waste heat (120-180℃) to drive molecular sieve regeneration, saving 85% more energy than electric heating.

CORE ADVANTAGE

Advantage CategoryDescription
Customized on DemandMeets special working conditions; provides professional non-standard customization
Low CostAdopts cyclic regeneration process; significantly reduces usage costs
High StabilityDouble-tower structure with small pressure fluctuation; low noise and continuous gas supply
Fully Automatic OperationEasy to operate, reducing labor input; improves efficiency
High SafetyPresets multi-level safety protection measures; supports automatic alarm
Low Failure RateMaintains low failure rate after 10,000 hours of operation; nearly maintenance-free durability

TECHNICAL STRENGTH

Leading Adsorption Dehydration Technology

  • Uses high-performance molecular sieve adsorbents with high water absorption capacity and resistance to acidic gas (H₂S/CO₂) corrosion, ensuring deep dehydration with a dew point ≤ -70℃.
  • Features an original hot nitrogen regeneration process, reducing energy consumption by 30% compared to traditional electric heating regeneration, and integrates a waste heat recovery system to significantly improve energy efficiency.

Modular and Customized Design Capability

  • Core equipment adopts modular prefabrication, supporting rapid deployment (installation cycle shortened by 50%) and adapting to diverse scenarios such as offshore platforms, onshore gas fields, and LNG pre-treatment.
  • Can customize single-tower, double-tower, or multi-tower parallel systems according to customer needs, with a treatment capacity ranging from 10,000 to 1,000,000 Nm³/d, flexibly matching gas fields of different scales.

Intelligent Control and Remote Operation & Maintenance

  • Equipped with a PLC+IoT intelligent control system to monitor key parameters such as pressure, temperature, and dew point in real time, supporting fault early warning and automatic adjustment.
  • Optimizes the adsorption-regeneration cycle through cloud big data analysis, extending the service life of molecular sieves and reducing operation and maintenance costs by 10%-15%.

Energy-Saving and Environmental Protection Technology

  • Features zero-emission design for regenerated tail gas, complying with EU CE, US EPA, and other environmental standards.
  • Energy consumption is 25%-40% lower than that of traditional Triethylene Glycol (TEG) dehydration systems, helping customers achieve carbon emission reduction goals.

Long-Cycle Operation Reliability

  • Molecular sieves adopt anti-pulverization coating technology, with a service life of over 5 years, reducing replacement frequency.
  • Key components (such as valves and instruments) are selected from international first-tier brands (e.g., Siemens, Emerson), with a Mean Time Between Failures (MTBF) of over 100,000 hours.

Strong R&D and Engineering Experience

  • Possesses 19+ patents for dehydration technology and software copyrights; the R&D team is led by doctors and cooperates in-depth with universities and colleges.
  • Has over 1,000 successful cases worldwide, covering extreme working conditions such as high-sulfur gas fields in the Middle East and low-temperature environments in the Arctic.

Product Advantage Comparison

IndicatorYipu SystemTraditional Condensation MethodCompetitor Adsorption MethodMembrane Separation Method
Dew Point-40℃ (stable)-10℃-30℃ (requires frequent regeneration)-20℃ (high energy consumption)
VOCs Recovery Rate≥95% (benzene series)≤60%80% (but adsorbents prone to poisoning)40-70%
Energy Consumption0.05 kWh/Nm³ (comprehensive)0.3 kWh/Nm³0.2 kWh/Nm³0.25 kWh/Nm³
Anti-Fouling CapacityResists 200 mg/m³ dust / 3000 ppm H₂SRequires pre-installed fine filtrationClogs when dust ≥ 50 mg/m³Membrane contaminated when oil mist ≥ 1 ppm
Maintenance Cycle5 years (molecular sieve)Monthly heat exchanger cleaningAdsorbent replacement every 3 monthsMembrane module replacement every year

Typical Case

Project Name: 300,000 Nm³/h Catalytic Cracking Exhaust Gas Treatment in a Refinery

Working Conditions

  • Components: Water-saturated, containing 1.2% benzene, 2000 ppm H₂S, and 80 mg/m³ dust
  • Requirements: Benzene recovery ≥ 90%, dew point ≤ -30℃, emissions meet GB 31570

Results

  • Benzene recovery rate of 96.5%, dew point of -38℃
  • Molecular sieves have been in operation for 4 years without replacement

Economic Benefits

  • Annual recovered benzene value reaches 32 million RMB
  • Saves 18 million RMB annually in sewage fees and equipment maintenance costs