Workshop KK
New to EHS/101 Basics … Air Pollution Control 101 – Selecting, Operating and Maintaining Scrubbers, Baghouses and Thermal Oxidizers
Wednesday, March 25, 2020 11:15 a.m. to 12:30 p.m.
Workshop KK New to EHS/101 Basics Air Pollution Control 101 - - PDF document
Workshop KK New to EHS/101 Basics Air Pollution Control 101 Selecting, Operating and Maintaining Scrubbers, Baghouses and Thermal Oxidizers Wednesday, March 25, 2020 11:15 a.m. to 12:30 p.m. Biographical Information Beau Carder,
New to EHS/101 Basics … Air Pollution Control 101 – Selecting, Operating and Maintaining Scrubbers, Baghouses and Thermal Oxidizers
Wednesday, March 25, 2020 11:15 a.m. to 12:30 p.m.
Biographical Information
Beau Carder, Mechanical Engineer, FerroGlobe PO Box 157, Beverly, OH 45715 740-984-8541 bcarder@ferroglobe.com Arnie T. Beringer, Owner & Managing Partner CEECO Equipment, Inc., Cincinnati, OH 513-709-8444 Fax: 513-672-0045 aberinger@ceecoequipment.com WWW.CEECOEQUIPMENT.COM Arnie began his career as an intern for the Ohio EPA (RAPCA) while he was attending the University of Dayton pursuing a Degree in Environmental Engineering. After spending an additional year with Ohio EPA after graduation, Arnie worked as an environmental engineer for Navistar for approximately 3 years in both their Springfield and Columbus
Chemical at their pigment plant operation in Cincinnati. For the next 16 years he had various plant and regional EHS management positions and last served as the Corporate EHS Compliance Assurance Manager for the North American operations for Sun
Equipment, as a manufacturer’s sales representative specializing in air pollution control and process equipment solutions. Arnie is a longtime member of the Air & Waste Management Association where he has served as the President of the Southwest Ohio Chapter on 3 separate occasions including currently. Ron Hawks, Process Engineering Manager and a Principle QSEM Solutions, Inc. (A Trinity Consultants Company) 919-848-4003 rhawks@qsemsolutions.com
including capture hooding, ducting systems, scrubbers, fabric filters, electrostatic precipitators, and afterburners. He has conducted numerous internal inspections of equipment and consults regularly on system performance with industrial clients across the US. His intense knowledge of the processes within steel, coke, lime, chemical, and cement facilities, among others facilitates insight into the interaction between the processes and collection systems. His process, mechanical and collection system understanding often provides a clear path to mitigate air compliance issues driven by these complex interactions. Mr. Hawks has completed several control equipment evaluations and upgrades at integrated steel mills and mini-mills, coke batteries, cement facilities, and other industries to achieve compliance with their air requirements. His experience includes thermal systems such as afterburners, RTO’s, Cement kilns, Lime kilns, abatement systems, industrial process evaluations, and other air pollution control
and a B.S. in Aerospace Engineering, and has authored many papers on these subjects through the A&WMA and IEEE, among others.
and Maintaining Scrubbers, Baghouses, and Thermal Oxidizers.
Arnie T. Beringer – CEECO EQUIPMENT, Inc aberinger@ceecoequipment.com 513-709-8444 Ron Hawks – QSEM Solutions, Inc. (A Trinity Consultants Company) rhawks@qsemsolutions.com 919-848-4003 Beau Carder - FerroGlobe bcarder@ferroglobe.com
1
– Dust Collectors – Scrubbers – Electro Static Precipitators (ESP, WESP)
– Scrubbers/Semi-Dry Scrubbers – Dry Sorbent Injection (DSI) – SNCR, SCR
2
– Scrubbers (Not very common) – Thermal Oxidation (Recup) (Incinerator) – Regenerative Thermal Oxidizer (RTO) – Catalytic Thermal Oxidizer (CTO) – Carbon Adsorption – VOC Concentrator
3
– Pressure Drop – higher is desired (5”wg to over 400” wg) – Particle Size – mass is more important than diameter – Water Flow – water must collide with particles – Entrainment Separator – ensure uniform flow
BIOMASS BOILER VENTURI SCRUBBER
SO2 GAS ABSORPTION SYSTEM
Scrubbers Thermal Oxidation Direct-Fired Regenerative Thermal Oxidation (RTO) Regenerative Catalytic Oxidation (RCO) Carbon Adsorption VOC Concentrator
concentrations (typically less than 3-5% LEL)
5% LEL or greater
– Oxidation conditions
– Regenerator flow valving (leakage)
media
Fabric Filter Design, Operations and Maintenance- MEC Conference March, 2020
Ronald Hawks Managing Consultant RHawks@ trinityconsultants.com
˃ Particles are captured by interception,
˃ Dust layer builds on the surface of the media ˃ Particles are removed by cleaning the
Particle Collection in Fabric Filters (cont.)
Particle Collection in Fabric Filters (cont.)
Particle Collection in Fabric Filters (cont.)
˃ Fabric media is specified based on the gas
Temperature Moisture Acid gases
˃ Media is also selected based on the particle
Abrasion Particle size Condensible fraction
˃ Required emission limits for the source
Mass emission-lb./ hr. Concentration-gr./ aCF
˃ Natural fiber
˃ Used to improve performance from abrasion,
Natural/ synthetic resins include: poly vinyl
Teflon S
˃ Defined by filter cleaning method and
S
Reverse air Pulse j et Cartridge Vent filter
Mechanical Shaker and Reverse Air Baghouses
Bags held by frame above the bags with dust
Low to medium air to cloth ratio Typically applied to metal fumes at very low
Multi-compartment application field-erected
Technology used in the mid-1980’s Being replaced by pulse j et designs
Poor bag tension resulting in inadequate
Accumulations of dust in tube sheet thimbles Abrasion above the thimbles due to high
Deposits on the clean side tube sheet when
Bags mounted on cages below the tube sheet
Dust removed by compressed air pulse
Cleaning accomplished either as a
Continuous filter operation during pulse
Higher air/ cloth ratio achieved due to higher
Pre-engineered or field erected (multi-
Fabric failure due to abrasion and/ or cage to
Moisture preventing cake release Over-cleaning resulting in fabric failure Fire due to spark carryover Fabric blinding/ high static loss Diaphragm failure
S
Timer failure Oil/ water in the compressed air system
Dust collected on either inside or outside
Cleaning via compressed air pulse High cloth to air ratio Typically low gas volume applications Pleated fabric used to increase surface
S
Low air/ cloth ratio May be natural draft or with an ID fan Primarily used to capture dust from silo
S
Intermittent use/ on-demand
Inadequate pulse cleaning High gas stream moisture Inadequate Cleaning cycles S
tart-up/ S hut-down procedures
Organic aerosols
˃ Fine dust re-suspended during pulse cleaning
resulting in fabric blending
˃ Can velocity controls resuspension of dust ˃ Possibly mitigated by off-line cleaning ˃ Can velocity defined by dust specific gravity
(lb./ ft3) and particle size
˃ Distributes dust over the bag surface ˃ Reduces abrasive failure
Dust Bulk Density lb./ft. Can Velocity ft./min. 30‐50 360 <30 300 <20 240 <10 180 <5 120 <.1 60
Fabric gas velocity-ft./ min. Fabric pressure loss-in. wg./ ft2 Particle penetration into fabric-blinding Can velocity-ft./ min. Cleaning effectiveness
Cake filtration on woven fabric Depth filtration on non-woven fabric
Follow NFP
A guidance (652) and (69)
Episodic (conductive) Oleophobic (oil resistant) coating S
tatic accumulation/ discharge
S
tainless steel ground wire/ tabs-static charge
Copper ground wire/ tabs-static charge
Carbon/ organics in dust S
Excessive temperature
Allows a non-fouling dust layer to be
Precoat materials include-
S
S
Over-filling of pyramidal hoppers due to
Filter cake density and particle size
Resuspension of dust due to inlet gas
Bag length during shaking cycle S
ine wave produced during shaking cycle
Cycle of cleaning/ duration (development of dust
cake)
Install bag with shaker bar a maximum height Deposits of dust on clean side of tube sheet Moisture dust caking
Operation of reverse air damper valves Bag tensioning (springs, caps, etc.) Number of anti-collapse rings per linear
Bag tensioning (?
Alignment of bag seams (45o to ?
Location of clean ring on thimble Dust accumulation on clean side tube
Filter cake hold up in bag after cleaning
Adj ust cleaning pulse sequence to reduce
Adj ust pulse pressure/ duration clean on
Diaphram failure due to moisture Cage corrosion/ wear Bag/ cage sizing (pinch) fabric type Cage design (number wires)
Filter Compliance Monitoring and Operation
Broken bag detectors Parametric monitoring External inspection Internal inspection Process monitoring
Filter Compliance Monitoring and Operation (cont.)
Preventive maintenance Pre-active (?
Data logging and trending
Damper action/ leakage Bag tension Bag flex during cleaning Cleaning cycle Bag seam alignment
Pulse valve inspection Can velocity verification for dust
type/ density
Cage corrosion damage/ wear Bag/ cage j et-pinch
Bag seam alignment Bag clamp location Bag pinch for material type Correct cage wire count for fabric