Workshop X Control Devices and Evaluation 101 The Basics of - - PDF document

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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

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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.

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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

  • peration 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.
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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

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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

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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

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Fabric Filter (FF) Systems

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Fabric Filter Technology

Reverse Air

  • Negative Pressure
  • Positive Pressure

Pulse Jet

  • High Pressure Pulse
  • Medium Pressure Pulse
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Reverse Air Baghouses

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1,000,000 ACFM Reverse Air Baghouse EAF Steel System (Ohio)

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Reverse Air Baghouse

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 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 FILTERS

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Pulse Jet Fabric Filter Design (<20’ bags)

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Walk-in Plenum or Roof Door Access SIDE INLET WITH DUAL DIRECTION BAFFLE

Side Dual Inlet Design for Long Bags (>20 ft)

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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

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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

Pulse Jet Baghouse Design

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Cages – 10 wire vs. 20 wire

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Filter Bag Installation

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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

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Pulse Jet Baghouse Photos

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Sample view of Roof-top door Project

B&W CFB Project Arkansas River Power 224,604 ACFM @ 303°F

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Pulse Jet Baghouse – 435,000 acfm from a CFB Colver, PA 435,000 ACFM @ 330°F

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Pulse Jet Baghouse - 442,000 ACFM from CFB

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Biomass Project – Aiken, SC

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Dry Sorbent Injection (DSI)

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Lime Trona SBC

Carbon and Sorbent Injection Process Flow

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PAC B-PAC

Injection Grid

  • 50% to 80% SO2 Removal
  • 95+% SO3 Removal
  • 98% HCl Removal
  • Hg to 1.2 lb/TBTU

FF or ESP

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Activated Carbon Injection (ACI)

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Semi-Dry Scrubber

 The Semi-Dry Scrubber treats Industrial or Utility process gas streams, removing:

  • Acid gases of
  • SO2
  • SO3
  • HCl
  • HF

 Uses alkali scrubbing media:

  • calcium hydroxide slurries
  • sodium-based solutions

 Used with downstream baghouse

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Wet Scrubber Technology

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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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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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Packed Bed Scrubber

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BIOMASS BOILER VENTURI SCRUBBER

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SO2 GAS ABSORPTION SYSTEM

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

VOC CONTROL TECHNOLOGIES

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BIO-OXIDATION MEDIA

Types

  • Natural Bio-active Media
  • Original Technology
  • Dual-BioPhase™ Synthetic Media
  • Technology Advancement
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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

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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

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EARLY BIO-FILTER DESIGN

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  • Bed Compaction
  • Media Replacement Cycle
  • Proper moisture control is critical
  • Difficult to monitor for removal efficiencies
  • Limited Surge Loading Capability/Efficiency
  • Limited Upper VOC Concentration

Capability 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

EARLY BIO-FILTER DESIGNS

Bed Compaction

Channeling Channeling

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EARLY BIO-FILTER DESIGNS

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DUAL-BIOPHASE™ MEDIA

Microorganisms and Nutrients are not Captive Within the Media but Immobilized On a Treated Synthetic Media Surface. Biomass Can be Continually Separated from Media Biomass Growth does not Cause Media Settling

  • Stable ΔP

Media Replacement is not Required to Replenish Nutrients

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Media Height is Not Limited to Maintain Proper Moisture Content Higher Capacity for Contaminants

  • Handles <5000 ppmv in Gas Phase

DUAL-BIOPHASE™ MEDIA

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MEDIA COMPARISON

Evaluation Category Organic Media Dual-BioPhase™ Synthetic Media

Microorganisms and Nutrients are Restrained within Media Yes No Media Replacement is Required to Replenish Nutrients Yes No Media needs Continually Fluffed to Obtain Porosity Yes No Biomass Growth Causes Media Settling Yes No Continually Increasing ΔP Yes No Maintaining Optimal Water Content is Crucial Yes No Media Height Limited to Maintaining Proper Moisture Content Yes No Capacity for Contaminants - ppmv <50 <5000 Limited Capacity to Neutralize Acids Yes No

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Biofilm – Biomass - Slough off

BIOFILM

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Water Soluble Pollutants are Treated in the Liquid Phase. Less Soluble Pollutants are Treated in the Gas Phase Nutrient laden sump solution is continuously recirculated throughout the upper chamber. The “Sump” serves as a continuous – extended waste water treatment chamber supporting the oxidization

  • f all water phase VOC’s, excess

biomass and other water borne,

  • rganic compounds.

WHAT IS A DUAL-BIOPHASE™ SYSTEM ?

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ADVANCED “BIO-OXIDATION”

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SUMMARY

 Dual-BioPhase™ System:

  • Greater oxidation efficiency
  • Higher capacity for contaminants (100 times )
  • Lower operating cost, increases flow capacity
  • Has a smaller footprint (3 - 6 times)
  • Essentially no maintenance
  • No media change out required
  • Easily maintains pH neutrality
  • Self contained biomass growth
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Thank You!! Question or Additional Information:

Arnie Beringer, Owner, CEECO Equipment, Inc. aberinger@ceecoequipment.com 513-709-8444 www.ceecoequipment.com Ron Hawks, Process Manager, QSEM Solutions, Inc. rhawks@qsemsolutions.com 919-848-4003 www.qsemsolutions.com