NEWS RELEASE                                                                                        SEPTEMBER 2016

The Catalytic Filter will have a Major Impact on the Fabric Filter, Scrubber, Precipitator, NOx and FGD Markets

The catalytic filter has the potential to change air pollution markets in a major way. Catalytic filters remove both NOx and particulate in one device. Over the last 10 years they have slowly gained acceptance in many small applications.  The first large scale commercial installation in a cement plant is undergoing testing.  Coal-fired power plants are now evaluating this technology for some near-term large projects.  Because the catalytic filter can be used in conjunction with direct sorbent injection, it can remove the acid gases, NOx, and fine particulate.  It can operate at 350oF with long fiberglass bags or at 850oF with shorter ceramic fiber bags. By combining three pollution control devices into one, a large power plant could save more than $200 million in up front capital expenditures.


Current Revenues $ Billions

Potential Impact %

Type of Impact (positive +, negative -)

Fabric Filter       13      60             +
NOx Control       18      50             -
FGD (Power)        3      40             -
Scrubber (Industrial)        7      20             -
Precipitator        6      20             -
Heat Recovery      10      50           + -

It is early in the growth cycle so it is unclear who will be the big winners and losers.   Fabric filter system suppliers such as FLSmidth can capture the lion’s share of the revenue.  On the other hand, the catalyst suppliers such as Haldor Topsoe can play either a minor or major role.  System suppliers such as Mitsubishi/Hitachi can also seize the opportunity. So far the most active participants have been the Filtration Group, Tri-Mer, FLSmidth and Haldor Topsoe.

Both industrial scrubbers and power plant flue gas desulfurization (FGD) markets will be impacted. The lower capital cost of the catalytic filter with direct sorbent injection will have to be weighed against salable byproducts such as gypsum.  The negative aspect of the DSI/catalytic filter is the mixture of dust and sulfates.  In general, the large power plants with a likely buyer of wallboard quality gypsum will want to stick with the present wet FGD.  However, suppliers of dry FGD systems could see their market disappear.

One of the biggest impacts will be on heat recovery.  If the conventional air pre-heater suppliers were to deal with clean hot 850oF gas, they could redesign their units to eliminate most of the air in leakage and can also offer economical designs to extract most of the rest of the heat in the flue gas.  Reducing the outlet temperature to 150oF instead of 350oF would improve power plant efficiency by as much as 2 percent.

Each of the McIlvaine market reports is evaluating the impact of this new technology.  Also the Power Plant and other Decision Guides for end users are providing intensive coverage of the technical developments.

1ABC Fabric Filter

2ABC Scrubber/Adsorber/Biofilter Knowledge Systems

3ABC FGD and DeNOx Knowledge Systems

4ABC Electrostatic Precipitator Knowledge Systems

N035 NOx Control World Market

44I Power Plant Air Quality Decisions