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, 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.
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
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
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
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
RTO Features • Lower fuel consumption • Lower Products of Combustion • Lower NO x 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%
Gas Flow Through the RTO – Forced Draft
Gas Flow Through the RTO – Induced Draft
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)
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
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 of 0.75 seconds and oxidation temperature of approximately 1600 degrees F (for non- halogenated compounds).
Fabric Filter Design, Operations and Maintenance- MEC Conference March, 2020 Ronald Hawks Managing Consultant RHawks@ trinityconsultants.com
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
Particle Collection in Fabric Filters
Particle Collection in Fabric Filters (cont.)
Particle Collection in Fabric Filters (cont.)
Particle Collection in Fabric Filters (cont.)
Fabric Construction Woven Felted (non-woven) Membrane
Fabric Construction (cont)
Fabric Media Selections ˃ Fabric media is specified based on the gas stream properties— Temperature Moisture Acid gases
Fabric Media Selections ˃ Media is also selected based on the particle properties— Abrasion Particle size Condensible fraction
Fabric Media Selections Limits ˃ Required emission limits for the source include: Mass emission-lb./ hr. Concentration-gr./ aCF
Woven Filters
Types of Fabric Fiber ˃ Natural fiber --Cotton (woven) --Wool (woven/ felted) --Rayon (cellulose/ woven)
Petroleum Polymers Nylon (woven) Polyester (woven) Aramid (nomex) Acrylic Polypropelyne
Mineral Based Glass fiber Ceramic S tainless S teel
Special Application PPS (polyethylene sufide? ) Teflon (fluorocarbon) P84 (polyamide) membrane
Chemical Compatibility Factors
Chemical Compatibility Factors (cont.)
Chemical Compatibility Factors (cont.)
Chemical Compatibility Factors (cont.)
Chemical Compatibility Factors (cont.)
Chemical Compatibility Factors (cont.)
Chemical Compatibility Factors (cont.)
Chemical Compatibility Factors (cont.)
Chemical Compatibility Factors (cont.)
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
Types of Fabric Filters ˃ Defined by filter cleaning method and configuration S haker Reverse air Pulse j et Cartridge Vent filter
Shaker Filter Arrangement
Mechanical Shaker and Reverse Air Baghouses
Characteristics of Shaker Type Fabric Filter System 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 of bag from top
Common Failure Mechanism for Shaker 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
Reverse Air Filter Arrangement
Reverse Air Baghouse
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