Evaporative Flue Gas Treatment Systems 2025: Surprising Growth Drivers & Future Disruptions Revealed

Table of Contents

• Executive Summary: Key Findings and 2025 Outlook
• Market Size, Segmentation, and Forecasts to 2030
• Emerging Technologies & Breakthrough Innovations
• Regulatory Landscape: New Rules Shaping System Demand
• Leading Players: Manufacturer Strategies & Partnerships
• End-User Industries: Power, Cement, Waste, and Beyond
• Cost-Benefit Analysis and ROI Trends
• Sustainability Drivers: Decarbonization and Water Use
• Regional Hotspots: Growth Opportunities by Geography
• Future Outlook: Disruptive Trends and Long-Term Scenarios
• Sources & References

Executive Summary: Key Findings and 2025 Outlook

Evaporative flue gas treatment systems are increasingly integral to industrial emissions control, driven by tightening environmental regulations and a global push toward decarbonization. In 2025, the sector is experiencing robust growth, particularly in regions implementing stricter limits on sulfur oxides (SOₓ), nitrogen oxides (NOₓ), and particulate matter. These systems, which commonly employ spray dryers and conditioning towers, are favored for their ability to efficiently reduce acid gases and particulates from flue gas streams, especially in coal-fired power, waste-to-energy, and cement industries.

A key finding in 2025 is the acceleration of technology upgrades, as plant operators seek both compliance and operational efficiency. Leading manufacturers such as Babcock & Wilcox Enterprises, Inc. and ANDRITZ GROUP are reporting increased demand for next-generation evaporative systems, which integrate advanced control systems and materials for enhanced durability and lower water consumption. Babcock & Wilcox, for instance, has highlighted new contracts for its SPIG dry and wet cooling solutions, reflecting the market’s focus on flexible, hybrid approaches to flue gas conditioning.

In Asia-Pacific, rapid industrialization and urbanization are resulting in significant investments in air pollution control infrastructure. Major projects in China and India utilize evaporative systems to meet national emission standards, with local suppliers such as Ducon Environmental Systems expanding their portfolios to address both new installations and retrofits of existing plants. Meanwhile, in Europe, compliance with the Industrial Emissions Directive (IED) is driving upgrades and modernization, with companies like Hitachi Energy delivering integrated flue gas treatment solutions to utilities and waste-to-energy operators.

A notable trend for 2025 is the integration of digital monitoring and predictive maintenance tools, which enable real-time optimization of evaporative processes and preemptive identification of maintenance needs. This digitalization is expected to reduce operational costs and downtime, increasing system reliability and regulatory compliance. Furthermore, the adoption of modular system designs is making it easier to scale and adapt solutions for different industrial applications.

Looking ahead to the next few years, the outlook for evaporative flue gas treatment systems remains strong. Global decarbonization policies, coupled with aging infrastructure in developed markets, are expected to sustain demand for both new installations and system retrofits. Ongoing research into water-saving technologies and hybrid treatment configurations is likely to further enhance the competitiveness and sustainability of these systems, positioning them as a key enabler of industrial air quality management through 2025 and beyond.

Market Size, Segmentation, and Forecasts to 2030

Evaporative flue gas treatment systems are a critical component in the ongoing global effort to reduce industrial air pollution, particularly from sectors such as power generation, cement, and waste-to-energy. As of 2025, the market for these systems is experiencing steady growth, driven by increasingly stringent emissions regulations, growing adoption of waste incineration, and the expansion of industrial capacity in Asia-Pacific, Europe, and North America.

Segmentation of the evaporative flue gas treatment market is typically based on application (e.g., power plants, cement plants, waste-to-energy facilities, and metallurgical industries), technology type (such as semi-dry and dry processes), and regional demand. The semi-dry process, often employing spray absorbers or dry scrubbers, is gaining preference due to its efficiency in removing acid gases and adaptability to retrofit projects. Leading suppliers—including ANDRITZ, Babcock & Wilcox Enterprises, Inc., and Hamon—offer diverse system configurations tailored to industry-specific requirements.

Recent years have seen notable projects and deployments, such as the supply of semi-dry flue gas treatment systems to large-scale waste-to-energy sites in Europe and Asia. For example, ANDRITZ has delivered multiple systems to municipal waste incinerators in Scandinavia and Germany, leveraging proprietary spray absorption and ash recycling technology. Similarly, Babcock & Wilcox Enterprises, Inc. continues to expand its footprint in North America and Asia with its SPIG and DynaGrate technologies—both focusing on increasing mercury and dioxin removal efficiency.

In terms of market size, while specific revenue figures are proprietary, industry sources indicate a multi-billion-dollar global market that is projected to grow at a compound annual growth rate (CAGR) in the mid-single digits through 2030. Growth is expected to be strongest in Asia-Pacific, particularly China and India, due to rapid infrastructure development and the implementation of stricter emissions control standards. Europe remains a mature but active market, with ongoing upgrades and replacements driven by the EU Industrial Emissions Directive and the move toward carbon neutrality (Hamon).

Looking forward to 2030, the market outlook for evaporative flue gas treatment systems is shaped by the interplay of regulatory pressure, technological innovation, and the global transition toward cleaner energy production. Suppliers are investing in R&D to enhance system efficiency, minimize water and reagent consumption, and enable integration with carbon capture solutions. As environmental compliance deadlines tighten and industrial operators seek cost-effective, high-performance emission controls, the demand for advanced evaporative flue gas treatment systems is set to remain robust across key industrial sectors.

Emerging Technologies & Breakthrough Innovations

Evaporative flue gas treatment systems are at the forefront of air pollution control technology, particularly as regulatory pressure intensifies and industries seek more efficient, cost-effective solutions for emissions abatement. In 2025, several significant advancements are shaping the field, driven by both technological innovation and evolving environmental standards.

A central trend is the integration of advanced atomization and spray control technologies, which enhance the efficiency of pollutant capture by optimizing droplet size and distribution within the absorber. Companies such as GE Vernova and Andritz have recently upgraded their evaporative systems to deliver higher removal rates for sulfur dioxide (SO₂), hydrogen chloride (HCl), and heavy metals, while reducing water and reagent consumption. These improvements are realized through real-time process monitoring and closed-loop control, enabling adaptive responses to fluctuating flue gas compositions.

In 2025, the deployment of hybrid systems—combining evaporative cooling with dry or semi-dry sorbent injection—is gaining traction. This approach offers enhanced flexibility for power plants and waste-to-energy facilities facing variable emission profiles. For example, Hitachi Energy has introduced modular evaporative units that interface seamlessly with existing dry flue gas treatment lines, providing rapid retrofitting options and scalability for future tightening of emission limits.

Materials science breakthroughs are also critical. The development of high-durability corrosion-resistant alloys for atomizers and vessel linings extends maintenance intervals and system longevity, especially in harsh chemical environments. Alfa Laval has reported successful field trials of novel anti-fouling materials that minimize scaling and particulate buildup, further enhancing operational uptime.

Digitalization continues to shape the outlook for evaporative flue gas systems. The application of predictive analytics, remote diagnostics, and cloud-based performance optimization enables operators to minimize downtime and reduce operational costs. Leading vendors such as Siemens Energy now offer digital twin solutions that simulate system behavior under different loads and environmental conditions, supporting more informed decision-making and proactive maintenance planning.

Looking ahead, the next few years are expected to see broader adoption of these innovations, with a particular focus on reducing greenhouse gas co-emissions, achieving compliance with stricter particulate matter and mercury standards, and improving water use efficiency—positioning evaporative flue gas treatment systems as a cornerstone of sustainable industrial operation.

Regulatory Landscape: New Rules Shaping System Demand

The regulatory landscape for evaporative flue gas treatment systems in 2025 is being reshaped by increasingly stringent air quality and emissions standards worldwide. These systems, which use water or alkaline solutions to cool and clean exhaust gases, have become a focal point for compliance within sectors such as waste-to-energy, cement production, and heavy industry.

In the European Union, the Industrial Emissions Directive (IED) and Best Available Techniques Reference Documents (BREFs) continue to set the benchmark for emissions from large combustion plants and waste incinerators. The 2024 revision of the Waste Incineration BREF introduced tighter limits for hydrogen chloride (HCl), sulfur dioxide (SO₂), and heavy metals, requiring operators to adopt advanced gas cleaning approaches such as evaporative quenching and scrubbing. Adherence to these standards is a top priority for plant operators, driving demand for high-performance evaporative systems from suppliers like ANDRITZ and Sulzer.

In the United States, the Environmental Protection Agency (EPA) finalized updates to the National Emission Standards for Hazardous Air Pollutants (NESHAP) for major source boilers and incinerators in 2024, imposing lower emission limits for acid gases and particulate matter starting in 2025. Facilities are now required to demonstrate compliance through continuous emissions monitoring and implementation of best available control technologies, with evaporative flue gas treatment often forming a core component. Companies such as Babcock & Wilcox have reported increased inquiries and project activity as operators respond to these rule changes.

The Asia-Pacific region, particularly China and India, is also seeing a regulatory tightening. China’s “Ultra-Low Emissions” standards for the cement and waste-to-energy sectors, updated in 2024, mandate stricter SO₂ and NO_x controls, accelerating the deployment of evaporative scrubbing systems. Major providers like Sinoma Energy Conservation have expanded their portfolios to address these demands. India’s Ministry of Environment, Forest and Climate Change (MoEFCC) continues to enforce phased reductions in particulate and acid gas emissions, promoting investments in advanced flue gas treatment among industrial operators.

Looking ahead, the trend toward even lower emission thresholds and comprehensive reporting is expected to continue, especially as decarbonization and public health concerns intensify. This regulatory pressure will likely stimulate further innovation and adoption of evaporative flue gas treatment systems globally, with system suppliers and technology developers positioning themselves to serve diverse regional requirements and evolving compliance needs.

Leading Players: Manufacturer Strategies & Partnerships

In 2025, the landscape of evaporative flue gas treatment systems is defined by the strategic initiatives of leading manufacturers as they respond to tightening environmental regulations and the evolving needs of the power, waste-to-energy, and industrial sectors. Global players are increasingly focusing on advanced system integration, expansion into emerging markets, and strategic collaborations aimed at technological innovation and service enhancement.

Key manufacturers such as ANDRITZ and Babcock & Wilcox Enterprises, Inc. have continued to refine their evaporative dry and semi-dry flue gas cleaning technologies. These firms highlight investments in digital monitoring and automation, enabling real-time process optimization and predictive maintenance to improve system reliability and efficiency. In 2024 and early 2025, Babcock & Wilcox Enterprises, Inc. secured several contracts in Europe and Asia for its dry FGD (Flue Gas Desulfurization) systems, underlining a strategy of targeting regions with newly strengthened emissions norms.

In the Asia-Pacific region, Hamon and Mitsubishi Power have expanded their presence through joint ventures and technology licensing agreements. For instance, Mitsubishi Power announced new partnerships in Southeast Asia in 2024, leveraging its evaporative flue gas cleaning portfolio to address the rising demand for cleaner industrial processes across the region’s rapid industrialization.

Innovation-driven partnerships are also notable, with companies like Valmet collaborating with utilities to deploy high-efficiency evaporative gas cleaning systems equipped with energy recovery and water reuse modules. These efforts align with sustainability objectives and stricter EU directives on emissions and resource management.

Looking ahead, manufacturers are expected to intensify their focus on modular and scalable system designs, facilitating easier retrofits in aging plants and supporting the circular economy. The outlook through 2027 points to increased supplier partnerships with EPC (Engineering, Procurement, and Construction) firms and local service providers, aiming to accelerate adoption while ensuring compliance with evolving emissions standards globally.

End-User Industries: Power, Cement, Waste, and Beyond

Evaporative flue gas treatment systems are increasingly integral to emissions control strategies across power generation, cement manufacturing, municipal waste incineration, and other heavy industries. In 2025 and the near future, the deployment of these systems is driven by tightening environmental regulations, decarbonization targets, and the persistent need to control pollutants such as SO₂, HCl, HF, and particulates.

In the power sector, especially coal and biomass-fired plants, evaporative coolers and spray dry absorbers are critical for pre-conditioning flue gases prior to downstream scrubbers and filters. Utilities in Europe and Asia are actively retrofitting existing plants to comply with stricter emission limits, such as the EU’s Industrial Emissions Directive (IED). For example, ANDRITZ AG supplies evaporative gas cooling systems that are being integrated into flue gas cleaning lines at thermal power plants to enhance SO₂ removal efficiency and optimize downstream equipment performance.

In the cement industry, evaporative gas coolers are standard for temperature control and acid gas removal, vital for meeting global emission standards. Leading suppliers such as FLSmidth are providing advanced evaporative coolers for rotary kilns and preheater towers, supporting both new installations and upgrades. The increasing use of alternative fuels in cement kilns is also driving demand for flexible flue gas treatment solutions that can handle variable gas compositions.

The waste-to-energy and municipal waste incineration sector continues to be a major adopter. Facilities are required to meet low emission thresholds for acid gases and dioxins. Companies like Hitachi Zosen Corporation are delivering turnkey evaporative cooling and dry sorption systems as part of comprehensive flue gas cleaning trains in new and retrofit projects, particularly in urban centers across Asia and Europe.

Beyond these core sectors, applications are expanding to metal smelting, chemical processing, and glass manufacturing. Evaporative flue gas treatment is being adopted for its ability to control temperature, prevent corrosion, and improve the efficiency of downstream filters and neutralization systems. For example, Scheuch GmbH is supplying evaporative cooling systems for metal and glass plants in Germany and Eastern Europe.

Looking ahead, the outlook for evaporative flue gas treatment systems remains robust through the late 2020s, with innovation focused on energy optimization, automation, and integration with digital monitoring tools. As regulatory frameworks tighten and industries pursue decarbonization, these systems will continue to be a key enabler of compliance and operational efficiency.

Cost-Benefit Analysis and ROI Trends

Evaporative flue gas treatment systems are increasingly being adopted across power generation, waste-to-energy, and heavy industrial sectors in 2025, driven by tightening emissions regulations and rising demand for sustainable operations. The core appeal of these systems lies in their capacity to efficiently cool and condition flue gases, enabling the removal of acid gases, heavy metals, and particulates before release into the atmosphere. A contemporary cost-benefit analysis reveals several key factors shaping return on investment (ROI) trends.

Initial capital costs for evaporative flue gas treatment systems typically vary depending on plant size, flue gas composition, and integration complexity. For example, modular spray dry absorber (SDA) installations offer scalability that can reduce upfront expenditure for smaller facilities, while custom-engineered systems for large-scale operations entail higher initial outlays. However, leading manufacturers such as Babcock & Wilcox Enterprises, Inc. and ANDRITZ AG emphasize that operational cost savings, including lower water and reagent consumption compared to wet scrubbing systems, are a major driver of positive ROI.

From an operational expenditure (OPEX) perspective, evaporative systems benefit from relatively simple maintenance regimes and reduced waste generation, as the byproducts are often dry and easier to handle. Valmet Oyj notes that the dry residue can frequently be disposed of as non-hazardous waste, further lowering lifecycle costs. Energy demands for these systems are also generally lower than those of alternative technologies, contributing to reduced total cost of ownership.

In terms of regulatory compliance and emissions performance, modern evaporative treatment units demonstrate high removal efficiencies for sulfur dioxide (SO₂), hydrogen chloride (HCl), and other acid gases—as well as mercury and dioxins—helping operators avoid costly penalties and future-proof their assets against evolving standards. Market leaders such as GEA Group AG report that their installations routinely achieve compliance with the latest European Industrial Emissions Directive (IED) and U.S. EPA standards.

Looking ahead to the next few years, the ROI for evaporative flue gas treatment systems is expected to strengthen as technology advances further improve efficiency and reduce reagent consumption. Additionally, as carbon pricing and emissions trading schemes expand globally, the financial incentives for investing in advanced gas cleaning solutions are set to increase. With a combination of regulatory, operational, and reputational benefits, these systems are positioned as a strategic investment for industrial plants aiming to balance compliance with cost-effectiveness in the near term.

Sustainability Drivers: Decarbonization and Water Use

Evaporative flue gas treatment systems are evolving rapidly as sustainability drivers such as decarbonization and water conservation exert increasing influence on industrial operations in 2025 and beyond. Traditionally employed in waste incineration, power generation, and certain chemical manufacturing sectors, these systems remove acid gases, heavy metals, and particulates from exhaust streams by spraying water or alkaline solutions into hot flue gases, thereby promoting pollutant removal via cooling and absorption.

The imperative for decarbonization is accelerating adoption of advanced evaporative scrubbing technologies. Operators are motivated by tightening emissions standards and ambitious net-zero targets set by governments worldwide. For example, leading technology providers such as Veolia Water Technologies are developing integrated evaporative systems that not only control acid gas emissions but also recover water and certain valuable byproducts, thus supporting circular economy objectives. In 2025, new projects—especially in Europe and Asia—are increasingly specifying evaporative flue gas treatment as part of comprehensive decarbonization strategies for municipal waste-to-energy and hazardous waste incineration plants.

Water usage is a critical concern for evaporative systems, as traditional designs can be water-intensive. To address this, technology manufacturers are introducing innovations to minimize water consumption. For example, Andritz AG offers systems that incorporate high-efficiency nozzles, optimized droplet sizing, and heat recovery modules that reduce the net water demand. Additionally, hybrid and zero-liquid discharge (ZLD) solutions are gaining traction to further limit water footprint and comply with stricter water discharge regulations, as highlighted in recent deployments by SUEZ Water Technologies & Solutions.

Looking ahead, the outlook for evaporative flue gas treatment systems is shaped by the convergence of emission reduction commitments and water stewardship. The market is expected to see continued growth in retrofit upgrades, as older facilities seek to align with emerging best practices and regulatory requirements. Furthermore, digitalization is enabling real-time monitoring and optimization of system water and reagent use, as showcased by Alfa Laval, which provides digital tools to optimize evaporative processes for both performance and sustainability.

In summary, the drive for decarbonization and responsible water management is pushing the evaporative flue gas treatment sector toward higher efficiency, lower water consumption, and integrated resource recovery. These trends are expected to intensify through 2025 and into the late 2020s, as stricter environmental targets and stakeholder expectations continue to reshape industrial air pollution control strategies.

Regional Hotspots: Growth Opportunities by Geography

The global market for evaporative flue gas treatment systems is poised for steady growth in 2025, driven by increasingly stringent emission regulations, especially in Asia-Pacific and Europe. These systems, which use water or reagent sprays to cool and condition flue gases and capture pollutants, are gaining traction in industries such as waste-to-energy, cement, and power generation.

Asia-Pacific remains the fastest-growing regional hotspot. In China, regulatory enforcement around SO₂, HCl, and dust emissions from thermal power and waste incineration plants has tightened. Major system suppliers such as Dürr Group and Babcock & Wilcox Enterprises, Inc. have reported expanded project pipelines in the region, responding to upgrades and retrofits at municipal and industrial facilities. India’s cement and steel sectors, facing stricter air quality norms, are also seeing increased adoption of evaporative conditioning and scrubbing solutions, as evidenced by installations from thyssenkrupp Industrial Solutions and Hitachi Zosen Corporation.

Europe continues to invest in advanced flue gas treatment systems to meet EU Industrial Emissions Directive (IED) benchmarks. Northern and Western European countries, with a mature waste-to-energy sector, are upgrading lines with high-efficiency evaporative cooling and scrubbing modules. Companies such as ANDRITZ Group and Valmet have ongoing projects in Germany, Sweden, and the UK, supporting both new and retrofit applications.

North America—while a relatively mature market—shows opportunity in the replacement and modernization of existing pollution control infrastructure. The US, driven by state-level air quality targets and lifecycle extension of older waste incinerators, is seeing renewed procurement activity, with Clean Air Engineering and Shaw Group among active suppliers for evaporative conditioning and scrubbing systems.

Looking forward, the outlook for 2025 and beyond is characterized by continued regulatory pressure, technology upgrades, and demand for flexible, modular systems that can be integrated with existing emissions controls. The Asia-Pacific region is expected to see the highest growth, while Europe and North America focus more on modernization and compliance-driven replacements.

Future Outlook: Disruptive Trends and Long-Term Scenarios

Evaporative flue gas treatment (EFGT) systems are poised for significant evolution as industries intensify efforts to meet ever-stricter emissions standards and sustainability goals through 2025 and beyond. These systems, which primarily use rapid cooling and conditioning of flue gases to facilitate removal of pollutants such as sulfur dioxide (SO₂), hydrochloric acid (HCl), and particulates, are being shaped by several disruptive trends.

A primary driver is regulatory pressure, especially in regions with ambitious decarbonization and air quality targets. The European Union’s Industrial Emissions Directive and the U.S. EPA’s recent advancements in air pollution controls are compelling industries to adopt high-efficiency gas cleaning technologies. As a result, leading EFGT providers such as Andritz AG and Babcock & Wilcox Enterprises, Inc. are investing heavily in R&D to advance system performance, modularity, and digital integration.

Digitalization and process automation are emerging as disruptive forces. EFGT systems are increasingly equipped with advanced sensors, real-time monitoring, and AI-based process optimization, enabling precise reagent dosing, lower water consumption, and predictive maintenance. For example, Siemens Energy offers digital solutions for process control that are being integrated into flue gas conditioning platforms to enhance operational efficiency and facilitate compliance reporting.

Water scarcity and resource efficiency are influencing system design. Innovations focus on reducing water usage, optimizing droplet dispersion, and integrating with water recovery units. Companies like Valmet are exploring hybrid systems that combine evaporative cooling with dry sorbent injection, aiming to maximize pollutant capture while minimizing environmental footprint.

Looking further toward the late 2020s, the convergence of EFGT systems with carbon capture technologies is anticipated, especially in power generation and waste-to-energy sectors. Pilot projects and early commercial deployments are underway where evaporative cooling prepares flue gas for downstream CO₂ capture, ensuring optimal temperature and humidity conditions for amine-based or solid sorbent systems. Companies such as Hitachi Zosen Corporation are actively developing integrated solutions that address multiple pollutants and greenhouse gases in a single treatment train.

In summary, the future of evaporative flue gas treatment systems is marked by cross-sectoral innovation, digital transformation, and integration with broader emission reduction strategies. As global regulations tighten and public scrutiny increases, EFGT technologies are set to play a central role in sustainable industrial operations through 2025 and the years immediately following.

Sources & References

• Babcock & Wilcox Enterprises, Inc.
• ANDRITZ GROUP
• Hitachi Energy
• GE Vernova
• Alfa Laval
• Siemens Energy
• Sulzer
• Valmet
• FLSmidth
• Scheuch GmbH
• GEA Group AG
• Hitachi Zosen Corporation
• Clean Air Engineering
• Shaw Group