Workshop KK New to EHS/101 Basics Air Pollution Control 101 - - PDF document

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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,


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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.

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SLIDE 2

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

  • Operations. After Navistar, Arnie took the environmental manager position at Sun

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

  • Chemical. In May of 2011 he left Sun Chemical to take over the family business, CEECO

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

  • Mr. Hawks is expert in the evaluation, operation, and maintenance of air control systems

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

  • systems. Mr. Hawks holds an M.M.E. in Mechanical Engineering, a B.S. in Chemistry,

and a B.S. in Aerospace Engineering, and has authored many papers on these subjects through the A&WMA and IEEE, among others.

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SLIDE 3
  • KK. Air Pollution Control 101 – Selecting, Operating

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

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Air Pollution Control Technologies

  • Particulate Matter (PM)

– Dust Collectors – Scrubbers – Electro Static Precipitators (ESP, WESP)

  • Acid Gases, NOx, SOx

– Scrubbers/Semi-Dry Scrubbers – Dry Sorbent Injection (DSI) – SNCR, SCR

2

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SLIDE 5

Air Pollution Control Technologies

  • Volatile Organic Compounds (VOC)

– Scrubbers (Not very common) – Thermal Oxidation (Recup) (Incinerator) – Regenerative Thermal Oxidizer (RTO) – Catalytic Thermal Oxidizer (CTO) – Carbon Adsorption – VOC Concentrator

3

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SLIDE 6

Venturi Scrubber

  • 4 Key Design Factors

– 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

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SLIDE 7

Venturi Scrubber

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Packed Bed Scrubber

  • Dirty gas comes into intimate contact with

scrubbing “liquor’

  • Specialized packing is utilized
  • pH and flow are important
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SLIDE 9

Packed Bed Scrubber

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SLIDE 10

BIOMASS BOILER VENTURI SCRUBBER

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SO2 GAS ABSORPTION SYSTEM

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SLIDE 12

 Scrubbers  Thermal Oxidation  Direct-Fired  Regenerative Thermal Oxidation (RTO)  Regenerative Catalytic Oxidation (RCO)  Carbon Adsorption  VOC Concentrator

VOC CONTROL TECHNOLOGIES

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SLIDE 13

RTO Features

  • Lower fuel consumption
  • Lower Products of Combustion
  • Lower NOx emissions
  • More applicable to high volume gas flow with low solvent

concentrations (typically less than 3-5% LEL)

  • No supplemental fuel is required for inlet concentrations of

5% LEL or greater

  • System expandable
  • High VOC removal efficiency (up to 99%)
  • Flexible for types of VOC containment in inlet gas exhaust
  • High thermal efficiency of 95%
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SLIDE 14

Gas Flow Through the RTO – Forced Draft

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SLIDE 15

Gas Flow Through the RTO – Induced Draft

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Regenerative Thermal Oxidization

The main factors affecting VOC removal efficiencies for RTO's are as follows:

– Oxidation conditions

  • Temperature
  • Retention time
  • Gas phase mixing

– Regenerator flow valving (leakage)

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SLIDE 17

RTO Performance

  • Up to 99% destruction efficiency
  • Up to 95% thermal energy recovery
  • Less than 50 ppm CO at 1600F
  • 0.04 lbs NOx/MMBTU natural gas consumption
  • Low pressure, particulate tolerant heat recovery

media

  • Self-Cleaning Bake-Out Feature
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Regenerative Thermal Oxidization

The residence time for most RTO systems range between 0.5 to 1.0 seconds and the oxidation temperature between 1500 degrees F to 2000 degrees F. For 99% VOC destruction efficiency. The optimum operating situation is residence time

  • f 0.75 seconds and oxidation temperature of

approximately 1600 degrees F (for non- halogenated compounds).

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Fabric Filter Design, Operations and Maintenance- MEC Conference March, 2020

Ronald Hawks Managing Consultant RHawks@ trinityconsultants.com

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Theory of Particle Capture Using Fibers

˃ Particles are captured by interception,

impaction and diffusion held by electrostatic forces

˃ Dust layer builds on the surface of the media ˃ Particles are removed by cleaning the

accumulating dust layers

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Particle Collection in Fabric Filters

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SLIDE 22

Particle Collection in Fabric Filters (cont.)

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Particle Collection in Fabric Filters (cont.)

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Particle Collection in Fabric Filters (cont.)

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SLIDE 25
  • Woven
  • Felted (non-woven)
  • Membrane

Fabric Construction

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Fabric Construction (cont)

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˃ Fabric media is specified based on the gas

stream properties—

 Temperature  Moisture  Acid gases

Fabric Media Selections

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˃ Media is also selected based on the particle

properties—

 Abrasion  Particle size  Condensible fraction

Fabric Media Selections

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˃ Required emission limits for the source

include:

 Mass emission-lb./ hr.  Concentration-gr./ aCF

Fabric Media Selections Limits

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Woven Filters

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SLIDE 31

˃ Natural fiber

  • -Cotton (woven)
  • -Wool (woven/ felted)
  • -Rayon (cellulose/ woven)

Types of Fabric Fiber

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SLIDE 32
  • Nylon (woven)
  • Polyester (woven)
  • Aramid (nomex)
  • Acrylic
  • Polypropelyne

Petroleum Polymers

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SLIDE 33
  • Glass fiber
  • Ceramic
  • S

tainless S teel

Mineral Based

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SLIDE 34
  • PPS

(polyethylene sufide? )

  • Teflon (fluorocarbon)
  • P84 (polyamide) membrane

Special Application

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Chemical Compatibility Factors

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Chemical Compatibility Factors (cont.)

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Chemical Compatibility Factors (cont.)

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Chemical Compatibility Factors (cont.)

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Chemical Compatibility Factors (cont.)

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Chemical Compatibility Factors (cont.)

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Chemical Compatibility Factors (cont.)

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Chemical Compatibility Factors (cont.)

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SLIDE 43

Chemical Compatibility Factors (cont.)

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Fiber Coatings

˃ Used to improve performance from abrasion,

chemical attack, etc.

Natural/ synthetic resins include: poly vinyl

chloride, cellulose acetate and urea-phenol

Teflon S

ilicon graphite

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SLIDE 45

Types of Fabric Filters

˃ Defined by filter cleaning method and

configuration

S

haker

Reverse air Pulse j et Cartridge Vent filter

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SLIDE 46

Shaker Filter Arrangement

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Mechanical Shaker and Reverse Air Baghouses

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SLIDE 48
  • Bags held by strap with dust collected on

inside surface

  • Low air to cloth ratio
  • Typically a single compartment
  • Used for fugitive dust from crushing,

conveying, grinding (i.e., large particles)

  • Cleaning mechanisms via mechanical shaking
  • f bag from top

Characteristics of Shaker Type Fabric Filter System

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SLIDE 49
  • Poor bag tension resulting in inadequate

cleaning

  • Accumulation of dust in tube sheet thimbles
  • Errosion above the thimble due to high

velocity

  • Deposits on clean side tube sheet restricting

air flow

Common Failure Mechanism for Shaker

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Reverse Air Filter Arrangement

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Reverse Air Baghouse

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Characteristics-Reverse Air Fabric Filter Systems

Bags held by frame above the bags with dust

collected on the inside surface

Low to medium air to cloth ratio Typically applied to metal fumes at very low

a/ c ratio

Multi-compartment application field-erected

systems

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Characteristics-Reverse Air Fabric Filter Systems (cont)

Technology used in the mid-1980’s Being replaced by pulse j et designs

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SLIDE 54

Common Failure Mechanisms for Reverse Air Systems

Poor bag tension resulting in inadequate

cleaning

Accumulations of dust in tube sheet thimbles Abrasion above the thimbles due to high

velocity (venture contracta)

Deposits on the clean side tube sheet when

penetration occurs

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Pulse Jet Arrangement

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Bags mounted on cages below the tube sheet

with dust held on the outside of the bags

Dust removed by compressed air pulse

inj ected thru the inside of the bag from the tube sheet

Cleaning accomplished either as a

compartment or separate bag rows

Characteristics of Pulse Jet Cleaning System

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SLIDE 57

Continuous filter operation during pulse

cleaning (on-line) or with module isolated (off-line)

Higher air/ cloth ratio achieved due to higher

cleaning intensity

Pre-engineered or field erected (multi-

module) depending on the required gas volume

Characteristics of Pulse Jet Cleaning System (cont.)

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SLIDE 58

Pulse Jet System Diagram

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SLIDE 59

Fabric failure due to abrasion and/ or cage to

cage contact

Moisture preventing cake release Over-cleaning resulting in fabric failure Fire due to spark carryover Fabric blinding/ high static loss Diaphragm failure

Common Failure Mechanisms for Pulse Jet

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SLIDE 60

S

  • lenoid failure

Timer failure Oil/ water in the compressed air system

Common Failure Mechanisms for Pulse Jet (cont.)

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Cartridge-type Filter System

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Dust collected on either inside or outside

  • f cartridge depending on manufacturer

Cleaning via compressed air pulse High cloth to air ratio Typically low gas volume applications Pleated fabric used to increase surface

area

Characteristic of Cartridge Systems

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SLIDE 63

S

ingle bag supported at the top with dust collected on inside of bag

Low air/ cloth ratio May be natural draft or with an ID fan Primarily used to capture dust from silo

vent or the low volume sources

S

elf-cleaning when air flow shut off

Intermittent use/ on-demand

Characteristic of Bin Vent Filters

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SLIDE 64

Inadequate pulse cleaning High gas stream moisture Inadequate Cleaning cycles S

tart-up/ S hut-down procedures

Organic aerosols

Filter High Pressure Drop Causes

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SLIDE 65

Pulse-Jet Baghouse

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Design Considerations (Can Velocity)

˃ 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

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Design Considerations (Inlet Design)

˃ Distributes dust over the bag surface ˃ Reduces abrasive failure

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Fabric Filter Design Considerations

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Fabric Filter Design Considerations

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Typical Acceptable Can Velocity

Dust Bulk Density lb./ft. Can Velocity ft./min. 30‐50 360 <30 300 <20 240 <10 180 <5 120 <.1 60

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Operating Principles

Fabric gas velocity-ft./ min. Fabric pressure loss-in. wg./ ft2 Particle penetration into fabric-blinding Can velocity-ft./ min. Cleaning effectiveness

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Fabric Filtration

Cake filtration on woven fabric Depth filtration on non-woven fabric

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Filter Dust Explosion Prevention

 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

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Filter Dust Combustion

Carbon/ organics in dust S

parks or embers from combustion source

Excessive temperature

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Fabric Precoating

Allows a non-fouling dust layer to be

placed on the fiber surface

Precoat materials include-

  • lime
  • flyash
  • diatomaceous earth
  • aluminum silicate
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SLIDE 76

Fabric Precoating (cont.)

S

  • me precoats can cause a problem when

non-particulate pollutants are in the gas stream (S O2, S O3, H2O, etc.)

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SLIDE 77

Multiple Module Collectors

S

egregation of dust into individual modules due to inlet duct design

Over-filling of pyramidal hoppers due to

particle segregation

Filter cake density and particle size

segregation between modules resulting in air flow imbalance

Resuspension of dust due to inlet gas

velocity

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SLIDE 78

Shaker Collectors

 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

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SLIDE 79

Reverse Air Collectors

Operation of reverse air damper valves Bag tensioning (springs, caps, etc.) Number of anti-collapse rings per linear

feet of bag

Bag tensioning (?

? ? ? Lb./ circumference feet of bag)

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SLIDE 80

Reverse Air Collectors (cont.)

Alignment of bag seams (45o to ?

? ? ? )

Location of clean ring on thimble Dust accumulation on clean side tube

sheet

Filter cake hold up in bag after cleaning

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SLIDE 81

Pulse Jet Collector

Adj ust cleaning pulse sequence to reduce

dust re-entrainment

Adj ust pulse pressure/ duration clean on

demand

Diaphram failure due to moisture Cage corrosion/ wear Bag/ cage sizing (pinch) fabric type Cage design (number wires)

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Filter Compliance Monitoring and Operation

Broken bag detectors Parametric monitoring External inspection Internal inspection Process monitoring

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Filter Compliance Monitoring and Operation (cont.)

Preventive maintenance Pre-active (?

? ) monitoring and preventive action

Data logging and trending

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Best Practice Reverse Air

Damper action/ leakage Bag tension Bag flex during cleaning Cleaning cycle Bag seam alignment

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Best Practice Reverse Air

Pulse valve inspection Can velocity verification for dust

type/ density

Cage corrosion damage/ wear Bag/ cage j et-pinch

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Best Practice Reverse Air (cont.)

Bag seam alignment Bag clamp location Bag pinch for material type Correct cage wire count for fabric