High-Power Diesel Generator Set Exhaust SCR Denitrification – Case Study

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Project Name: Exhaust Gas Treatment for 5 High-Power Diesel Generator Sets

Core Equipment: 5 Diesel Generator Set SCR Denitrification Systems

Raw Emission: NOx ≤ 3,500 mg/Nm³ (at 5% O₂)

Treatment Target: NOx ≤ 50 mg/m³

Technology Route: SCR (Selective Catalytic Reduction) Denitrification

1. Project Background
With the continuous advancement of air pollution prevention and control efforts, high-power diesel generator sets – widely used as critical standby power sources and peaking units – have drawn increasing regulatory attention due to their high-concentration nitrogen oxide (NOx) emissions during operation. Hebei Hanlan Environmental Technology Co., Ltd. successfully delivered five sets of SCR denitrification systems for high-power diesel generator sets, achieving a substantial reduction in NOx emissions from exhaust gas and providing robust technical support for regional air quality improvement.

2. Project Challenges
The five diesel generator sets in this project presented the following operational challenges:
High exhaust emission concentration: Raw NOx concentration reached up to ≤ 3,500 mg/Nm³ (at 5% O₂), far exceeding current environmental limits.
Strict temperature window: Exhaust gas temperatures ranged between 400 °C and 425 °C, requiring the denitrification catalyst to maintain high activity within this specific temperature range.
High reliability requirements: The system needed to prevent catalyst poisoning and ensure long-term, dependable operation.
End-to-end service needs: The customer required a turnkey solution covering design, manufacturing, commissioning, and training.

3. Solution
Hebei Hanlan provided a custom-engineered SCR denitrification system, offering a complete end-to-end solution from design through after-sales service – encompassing manufacturing, transportation, installation supervision, system commissioning, and operator training.
Scope of Supply: The supply scope began at the inlet flange of the flue gas mixing duct and ended at the outlet flange of the SCR reactor, including all gas, liquid, and electrical lines and piping within the system. All flanges and bolts were manufactured from carbon steel to ensure durability and reliability under demanding operating conditions.
Core Technology: The system utilised a dedicated denitrification catalyst designed specifically for internal combustion engines, featuring the following characteristics:
Operating temperature: 350 °C – 420 °C
Light-off temperature: ≥ 300 °C
Maximum withstand temperature: 450 °C (short-term exposure)
Excellent temperature adaptability to match generator exhaust fluctuations

4. Implementation Results
Following deep treatment through the SCR denitrification system, NOx emissions from the generator sets were dramatically reduced:
Before treatment: ≤ 3,500 mg/Nm³
After treatment: ≤ 50 mg/m³
Removal efficiency: 98.6%
All emission indicators met current stringent environmental requirements. The system has operated stably with no catalyst poisoning or efficiency degradation observed.

5. Operational Safeguards
To ensure long-term system stability, Hebei Hanlan established stringent requirements for key flue gas constituents, including:
Sulfur content
Alkali metal content
Dust loading
Siloxane content
By controlling flue gas composition upstream, catalyst poisoning is effectively prevented, ensuring sustained high-performance denitrification.

6. Customer Value
Regulatory compliance: NOx emissions reduced to below 50 mg/m³, ensuring smooth environmental acceptance and permitting.
High-efficiency purification: 98.6% removal efficiency delivers substantial reductions in regional air pollutant emissions.
Operational reliability: Dedicated catalysts matched to the 400 °C – 425 °C exhaust temperature range ensure consistent performance over extended service periods without degradation.
Hassle-free service: Full-chain coverage from design through training eliminates the need for the customer to coordinate with multiple vendors.

7. Case Summary

The successful implementation of this project validates Hebei Hanlan’s technical expertise and engineering experience in the field of ultra-low emission retrofits for high-power diesel generator sets. Through precise catalyst selection, a comprehensive scope of supply, and end-to-end service delivery, the project successfully reduced high-concentration NOx emissions to ultra-low levels, establishing a replicable and scalable solution for similar generator set environmental retrofits

Hebei Hanlan remains committed to continuous innovation and breakthrough advancements in environmental protection technology, contributing professional expertise to the global pursuit of cleaner air and the high-quality development of the environmental protection equipment manufacturing industry.