Workshop X Control Devices and Evaluation 101 … The Basics of Evaluating, Selecting and Understanding Common Control Devices Tuesday, March 21, 2017 3:30 p.m. to 4:45 p.m.
Biographical Information 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 two separate occasions, the last time having concluded in 2014. Ronald Hawks, QSEM Solutions, Inc. (QSEM) 6120 South Gilmore Road, Suite 204, Fairfield, OH 45014 Office: 513-742-8888 or 919-848-4003 Fax: 513-742-4444 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 as submitted many papers on these subjects through the A&WMA and IEEE, among others. Mt. Hawks is the Process Engineering Manager and a Principle at QSEM Solutions, Inc.
CONTROL DEVICES AND EVALUATION 101 The Basics of Evaluating, Selecting and Understanding Common Air Pollution Control Devices Arnie T. Beringer – CEECO EQUIPMENT, Inc aberinger@ceecoequipment.com 513-709-8444 Ron Hawks – QSEM Solutions, Inc. rhawks@qsemsolutions.com 919-848-4003 1
Air Pollution Control Technologies • Particulate Matter (PM) – Dust Collectors – Scrubbers – Electro Static Precipitators (ESP, WESP) • Acid Gases, NOx, SOx – Scrubbers – Dry Sorbent Injection (DSI) – SNCR, SCR 2
Air Pollution Control Technologies • Volatile Organic Compounds (VOC) – Scrubbers (Not very common) – Thermal Oxidation (Incinerator) – Regenerative Thermal Oxidizer (RTO) – Catalytic Thermal Oxidizer (CTO) – Carbon Adsorption – Bio Oxidation – VOC Concentrator 3
Fabric Filter (FF) Systems
Fabric Filter Technology Reverse Air • Negative Pressure • Positive Pressure Pulse Jet • High Pressure Pulse • Medium Pressure Pulse
Reverse Air Baghouses
1,000,000 ACFM Reverse Air Baghouse EAF Steel System (Ohio)
Reverse Air Baghouse
PULSE JET FABRIC FILTERS High Pressure Pulse Jet Filters • Filter bags typically 6” diameter, and range up to 20 ft in length • Pulse Header pressure regulated from 65 – 90 psig depending on filter bag material • Right angle pulse valves 1-1/2” to 2-1/2” Medium Pressure Pulse Jet Filters • Filter bags typically 5” diameter, and 26-32 ft in length • Pulse Header pressure regulated from 35 – 50 psig depending on filter bag material • Immersion pulse valves 3” to 4” • Used on large flow systems saving on footprint requirement at jobsites – Typical Utility Applications
Pulse Jet Fabric Filter Design (<20’ bags)
Side Dual Inlet Design for Long Bags (>20 ft) Walk-in Plenum or Roof Door Access SIDE INLET WITH DUAL DIRECTION BAFFLE
Cleaning System for Intermediate Pressure Pulse Jet BALANCED FORCE BLOWTUBE SYSTEM 25-35 psig P t = ½ pV 2 + P s Variable Orifice Sizes Relativ e Pulse Fixed Orifice Size Force 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Orifice Position
Pulse Jet Baghouse Design Typical Filter bag options Material Type Max. temp. 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
Cages – 10 wire vs. 20 wire
Filter Bag Installation
Computational Fluid Dynamics (CFD) 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
Pulse Jet Baghouse Photos
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
Pulse Jet Baghouse - 442,000 ACFM from CFB
Biomass Project – Aiken, SC
Dry Sorbent Injection (DSI)
Lime Trona Carbon and Sorbent Injection Process Flow SBC x FF or ESP PAC B-PAC Injection Grid • 50% to 80% SO 2 Removal • 95+% SO 3 Removal • 98% HCl Removal • Hg to 1.2 lb/TBTU
Activated Carbon Injection (ACI)
Semi-Dry Scrubber The Semi-Dry Scrubber treats Industrial or Utility process gas streams, removing: • Acid gases of • SO 2 • SO 3 • HCl • HF Uses alkali scrubbing media: • calcium hydroxide slurries • sodium-based solutions Used with downstream baghouse
Wet Scrubber Technology
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
Venturi Scrubber
Packed Bed Scrubber • Dirty gas comes into intimate contact with scrubbing “liquor’ • Specialized packing is utilized • pH and flow are important
Packed Bed Scrubber
BIOMASS BOILER VENTURI SCRUBBER
SO 2 GAS ABSORPTION SYSTEM
VOC CONTROL TECHNOLOGIES Scrubbers Thermal Oxidation Direct-Fired Regenerative Thermal Oxidation (RTO) Regenerative Catalytic Oxidation (RCO) Carbon Adsorption VOC Concentrator Bio-Oxidation
BIO-OXIDATION MEDIA Types • Natural Bio-active Media • Original Technology • Dual-BioPhase ™ Synthetic Media • Technology Advancement
NATURAL BIO-ACTIVE MEDIA Microorganisms and Nutrients are Captive within the Media Structure Biomass Cannot be Separated from Media Biomass Growth Causes Media Settling • Continually Increasing ΔP Media Replacement is Required to Replenish Nutrients Media needs Fluffed to Obtain Porosity
NATURAL BIOACTIVE MEDIA Maintaining Optimal Moisture Content within the Media is Crucial Media Height is Limited Due to Maintaining Proper Moisture Content • Results in Short & Large Cross-Sectional Media Bed Areas Limited Capacity for Contaminants • Handles <50 ppmv in Gas Phase Has Limitation to Neutralize Acids
EARLY BIO-FILTER DESIGN
EARLY BIO-FILTER DESIGNS A principle drawback to the early designs was the large footprint required. A large biofilter (~200,000 acfm ) may occupy an area the size of a football field Bed Compaction • Bed Compaction • Media Replacement Cycle Channeling Channeling • Proper moisture control is critical • Difficult to monitor for removal efficiencies • Limited Surge Loading Capability/Efficiency • Limited Upper VOC Concentration Capability
EARLY BIO-FILTER DESIGNS
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