Workshop L
Clean Air Act Challenges … Air Pollution Control …Identify, Operate and Optimize for EPA Compliance, Operational Flexibility, Operating Cost and Troubleshooting
Tuesday, March 26, 2019 11:15 a.m. to 12:30 p.m.
Workshop L Clean Air Act Challenges Air Pollution Control - - PDF document
Workshop L Clean Air Act Challenges Air Pollution Control Identify, Operate and Optimize for EPA Compliance, Operational Flexibility, Operating Cost and Troubleshooting Tuesday, March 26, 2019 11:15 a.m. to 12:30 p.m. Biographical
Clean Air Act Challenges … Air Pollution Control …Identify, Operate and Optimize for EPA Compliance, Operational Flexibility, Operating Cost and Troubleshooting
Tuesday, March 26, 2019 11:15 a.m. to 12:30 p.m.
Biographical Information
Micah S. Garrabrant, Senior Mechanical Engineer at the BOF AK Steel Corporation, 1801 Crawford St., Middletown, OH 45044 513-425-6258 Fax: 513-425-3867 Micah.Garrabrant@Aksteel.com Micah started his career as a Co-op student at the Steelmaking shop at AK Steel Middletown Works in 2008. Micah then hired on as the Baghouse Day Manager at the Basic Oxygen Furnace (BOF) in 2009 where his primary responsibility was managing the maintenance and compliance of the Title V permit at approximately 7 different baghouses at the BOF. Micah then progressed as the Water Treatment Day Manager at the BOF in 2011 where again he was responsible for maintenance and compliance with the water permit and stack testing. In 2013 Micah progressed into the Junior Mechanical Engineer position at the BOF and in 2018 progressed into the Senior Mechanical Engineer position where responsibilities included maintaining all of the equipment in the shop and still being closely associated with the Environmental aspects of the BOF. Micah is a graduate of Wright State University with a B.S. in Mechanical Engineering. 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 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.
Biographical Information
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.
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.
in Aerospace Engineering, and has authored many papers on these subjects through the A&WMA and IEEE, among others.
Identify, Operate and Optimize for EPA Compliance, Operational Flexibility, Operating Cost and Troubleshooting
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 Micah Garrabrant – AK Steel Micah.Garrabrant@aksteel.com
1
– Dust Collectors – Scrubbers – Electro Static Precipitators (ESP, WESP)
– Scrubbers – Dry Sorbent Injection (DSI) – SNCR, SCR
2
– Scrubbers (Not very common) – Thermal Oxidation (Incinerator) – Regenerative Thermal Oxidizer (RTO) – Catalytic Thermal Oxidizer (CTO) – Carbon Adsorption – VOC Concentrator
3
Reverse Air
Pulse Jet
https://youtu.be/4EyJX6JzBQ0
1,000,000 ACFM Reverse Air Baghouse EAF Steel System (Ohio)
High Pressure Pulse Jet Filters
filter bag material
Medium Pressure Pulse Jet Filters
filter bag material
jobsites – Typical Utility Applications
PULSE JET FABRIC FILTERS
Pulse Jet Fabric Filter Design (<20’ bags)
Walk-in Plenum or Roof Door Access SIDE INLET WITH DUAL DIRECTION BAFFLE
Side Dual Inlet Design for Long Bags (>20 ft)
25-35 psig
Cleaning System for Intermediate Pressure Pulse Jet
BALANCED FORCE BLOWTUBE SYSTEM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Orifice Position Relativ e Pulse Force
Fixed Orifice Size Variable Orifice Sizes
Pt = ½ pV2 + Ps
Typical Filter bag options
Material Type
Removal Chemical Bag-life Relative Oper./upset performance Resistance Cost Fiberglass woven 500/525°F Good A 2-3 years 1.0 Fiberglass woven 500/525°F Excellent A 3-4 years 2.5 w/ ePTFE membrane PPS (Ryton felt 375/425°F Very good A 4 years 1.5 / Procon) Aramid felt 385/425°F Very good C 3 years 1.6 (Nomex) P-84 felt 400/450°F Very good B 3 years 2.0 Chemical Resistance Code: A = Very Good B = Good C = Fair
Pulse Jet Baghouse Design
Cages – 10 wire vs. 20 wire
Filter Bag Installation
CFD Studies are performed on Baghouse System Projects with the
following steps:
Preliminary flow distribution design (based on previous
experience)
CFD Analysis and feedback of preliminary design Adjustment to design based on CFD feedback CFD Analysis and feedback on revised design Final review of CFD by Amerair, Galletta, and Lodge Confirm design and start procurement
Sample view of Roof-top door Project
B&W CFB Project Arkansas River Power 224,604 ACFM @ 303°F
Pulse Jet Baghouse – 435,000 acfm from a CFB Colver, PA 435,000 ACFM @ 330°F
Lime Trona SBC
Carbon and Sorbent Injection Process Flow
x
PAC B-PAC
Injection Grid
FF or ESP
The Semi-Dry Scrubber treats Industrial or Utility process gas streams, removing:
Uses alkali scrubbing media:
Used with downstream baghouse
Contact us at: (610) 323-7670
Contact us at: (610) 323-7670
– RTO – The RTO is sized for a specific SCFM (process flow) and thermal efficiency. Based upon the size of the RTO, ceramic heat recovery media is selected and
maximum destruction efficiency and minimal operating costs.
Contact us at: (610) 323-7670
– Also, the RTO if evaluated and designed properly can be expanded with minor modification to areas such as different heat recovery media.
Contact us at: (610) 323-7670
concentrations (typically less than 3-5% LEL)
5% LEL or greater
Contact us at: (610) 323-7670
Contact us at: (610) 323-7670
Contact us at: (610) 323-7670
– Oxidation conditions
– Regenerator flow valving (leakage)
Contact us at: (610) 323-7670
media
Contact us at: (610) 323-7670
Contact us at: (610) 323-7670
Access Door to Valve, ducts,cold face, and plenum Actuator and Solenoid Valve Hopper style cold face plenum:
distribution across the media
volume which increases destruction efficiency Inlet Manifold Outlet Manifold
Contact us at: (610) 323-7670
Includes additional valves, controls, timers and solenoids.
Contact us at: (610) 323-7670
Standard Burner Chamber Access Poppet Valve Access
Contact us at: (610) 323-7670
Allows entry and inspection of:
Contact us at: (610) 323-7670
Experience With Varying Types Of Heat Recovery Media
Contact us at: (610) 323-7670
25,000 SCFM RTO Skid Mounted design, minimizes space Achieved 99.6% DRE!
Contact us at: (610) 323-7670
– Chemistry is important – Precious metals catalyst – CFM is important. May be too costly at high flow
Contact us at: (610) 323-7670
cost for catalyst.
susceptible to high temperature excursions.
VOC loadings.
Contact us at: (610) 323-7670
Contact us at: (610) 323-7670
Contact us at: (610) 323-7670
Contact us at: (610) 323-7670
Important design parameters/variables for the successful
the limits for available catalytic oxidation systems
Contact us at: (610) 323-7670
Contact us at: (610) 323-7670
MEC Conference Sharonville, OH – March 26, 2019
Managing Consultant
˃ Scrubber technology for particulate control
Particle capture Droplet removal
˃ Methods of achieving the above have
Better water introduction Better demister technology
˃ System designs used by OEM’s have not
˃ Air/atomized and high pressure systems
˃ Ionized charging of water
˃ Condensation to produce small aerosols
Configuration of a Venturi Scrubber
˃ Characterize Uncontrolled Particle
˃ Define Required Control Efficiency
˃ Develop Design Considerations ˃ Determine Plant Constraints
˃ Particle capture mechanism
Droplet size (um) Static pressure (in wg) Liquid gas ratio (L/G)
˃ Water droplet separation
Mesh pad Chevrons Cyclonic separation
˃ The smaller the water droplet, the higher
˃ Droplets can be created by-
Shearing of sheet water (i.e. overflow weir) Preformed spray nozzles (hydraulic pressure) Air atomized nozzles
˃ Johnstone equation ˃ Infinite throat model ˃ Cut power method ˃ Contact power theory ˃ Pressure drop
0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00 120 150 300 450 750 1000 1500 2000 3000
%
water droplet diameter um
10um 5um
˃ ∆p=4X10-5(Vgt)2(L/G)
˃ % H2O at Saturation Dependent on Absolute
˃ % H2O at Saturation also Dependent on Gas
˃ Why important?
Water balance Saturated Gas volume Velocity thru demister
˃ Change in ambient barometer pressure
˃ Water Droplet Size Distribution ˃ Water Droplet Spatial Distribution in the
˃ Spray Nozzle Orientation During nozzle
˃ Pre-Saturation of Gas before Scrubber
˃ Sub-micron Particle Generation from
˃ Failure to remove water droplets after
˃ Water droplets contain both suspended and
˃ Impact of droplets can be determined by
˃ The lower the allowed mass emission rate, the
more significant droplet carry over becomes.
˃ A completely dry demister outlet cannot be
achieved without fouling and eventual failure.
˃ Build-up of dissolved solids in recirculated
water can result in visible plumes (NaCl, KCl, NH4Cl2 solids) which form submicron aerosols when droplets evaporate in the atmosphere.
˃ Packed bed counter-flow design ˃ Technology widely used in the chemical
˃ Control based absorption of gas in water using
˃ Effectiveness determined by diffusion rate,
˃ Absorption determined by the height of the
˃ Number of transfer units determine the
˃ Height of the transfer unit can be calculated
˃ Liquor rate- lb./hr-ft2 ˃ Gas rate- lb./hr-ft2 ˃ Packing design/type ˃ Pollutant characteristics
˃ Once thru ˃ Recirculated with blow down ˃ Recirculated with blow down and
NTU % Removal efficiency 0.5 39.34 1.0 63.21 2.0 86.46 3.0 95.02 4.0 98.17 5.0 99.33
˃ Pollutant HCl ˃ Water recirculated ˃ Water not neutralized ˃ Recirculation 192 gpm ˃ Blow down 10 gpm at pH of 0.45 ˃ Inlet gas volume 27,500 acfm at 122 oF
˃ Theoretical removal 97.3% ˃ Number of transfer unit-4.17 ˃ Height of transfer unit-1.2 feet ˃ Demister velocity- 339 ft./min
˃ HCl concentration-40 to 50 ppm ˃ Required HCl concentration-22 ppm ˃ Failure mechanisms
˃ High energy venturi scrubber-75 in wg ˃ Gas quench section before venturi throat ˃ ID fan handling wet flue gases ˃ Inertial and Chevron demister
˃ Heat duration 20 minutes ˃ Conditions at fan inlet change constantly due
˃ Flue gases composition CO, CO2, N2, H2O ˃ Fraction of gases as CO2 expressed as
˃ ID fan exhausting gases which are saturated
˃ Water vapor has a different density than air or
˃ Higher the gas temperature, the higher the
˃ As gas temperature increases the volume of
Temperature oF % moisture v/v % moisture lb/lb‐DA 70 2.46 0.0158 100 6.86 0.0459 150 25.36 0.2116 178 49.04 0.5992
500 1000 1500 2000 2500 ‐ 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 0.000 2.000 4.000 6.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000 F LAMBDA TIME
LAMBDA VS. OG TEMPERATURE
lambda 2 F
‐8 ‐6 ‐4 ‐2 2 4 ‐ 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 0.000 2.000 4.000 6.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000 LAMBDA TIME
LAMBDA VS. HOOD DRAFT
lambda 2 in wg
‐ 10,000.00 20,000.00 30,000.00 40,000.00 50,000.00 60,000.00 70,000.00 ‐ 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 0.000 2.000 4.000 6.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000 LAMBDA TIME
LAMBDA VS. ID FAN ACFM
lambda 2 ACFM
0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.06 ‐ 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 0.000 2.000 4.000 6.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000 LAMBDA TIME
LAMBDA VS. GAS DENSITY
lamdba 2 DENSITY
69 70 71 72 73 74 75 76 77 78 79 ‐ 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 0.000 2.000 4.000 6.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000 LAMBDA TIME
LAMBDA VS. VENTURI DIFFERENTIAL
lamdba 2 DENSITY
EPA/625/6-91/014
Practice for Design, 28th edition, ACGIH
Arnie Beringer, Owner, CEECO Equipment, Inc. aberinger@ceecoequipment.com 513-709-8444 www.ceecoequipment.com
Ron Hawks – QSEM Solutions, Inc. (A Trinity Consultants Company) rhawks@trinityconsultants.com 919-462-9693 919-500-9428 Micah Garrabrant – AK Steel Micah.Garrabrant@aksteel.com