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 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 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.
Biographical Information 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.
L. Clean Air Act Challenges: Air Pollution Control … 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
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 – VOC Concentrator 3
Fabric Filter Technology Reverse Air • Negative Pressure • Positive Pressure Pulse Jet • High Pressure Pulse • Medium Pressure Pulse
Reverse Air Baghouses https://youtu.be/4EyJX6JzBQ0
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
Regenerative Thermal Oxidizers Contact us at: (610) 323-7670
Design Philosophy – 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 optimum bed velocities are determined to achieve both maximum destruction efficiency and minimal operating costs. Contact us at: (610) 323-7670
Design Philosophy – 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
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% Contact us at: (610) 323-7670
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