air pollution control techniques for aerosol- and dust ... · bag house filters, filter media...
TRANSCRIPT
Department of Mechanical Process Engineering
Vienna University of Technology Institute of Chemical Engineering
Air Pollution Control Techniques for Aerosol- and Dust emissions
Wilhelm HoeflingerVienna University of Technology, Institute of Chemical Engineering,
Vienna, AUSTRIA
Presentation at the Tempus Retraining Meeting, Vienna, Austria, 15-19 Nov. 2010
Department of Mechanical Process Engineering
Vienna University of Technology Institute of Chemical Engineering
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Content• Dust, Aerosol:
Definitions,
European concentration regulations,
Dust measurement techniques
• Dust SeparatorsDifferent kinds of dust separators
Bag house filters,
Filter media
Standard test facilities for testing different filter media
Electrostatic enhancement of bag house filtration, hybrid filters
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Vienna University of Technology Institute of Chemical Engineering
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Definitions• Technically, dust or an aerosol are suspensions of fine
particles in a gas.
• Dust: particles in a gas below appr. 100 micrometer
• Aerosol: particles in a gas below 10 micrometer– Solid aerosol, liquid aerosol
– Smoke, haze: aerosol with high concentration
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Vienna University of Technology Institute of Chemical Engineering
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Definitions
Emission - Immission
Immission (mg/m 3)
Emission (mg/m3)
Department of Mechanical Process Engineering
Vienna University of Technology Institute of Chemical Engineering
Characterisation of Emissions and Immissions
• TSP: Total suspended particles [mg/m³]
• PM10: Particulate matter smaller than 10 µm [mg/m³]
• PM2,5: Particulate matter smaller than 2,5 µm [mg/m³]
• PM1: Particulate matter smaller than 1 µm [mg/m³] (USA)
Particle size: aerodynamic diameter
Department of Mechanical Process Engineering
Vienna University of Technology Institute of Chemical Engineering
Prof. Höflinger; Staubabscheiden 6
Aerodynamic diameter dae
dae = ρ1/2 . dreal
( ) 2
181: dgvStokes PTS ⋅⋅⋅⋅
= ρη
Aerodynamic diameter is the diameter of a sphere of unit density (1g/cc) that has the same gravitational settling velocity as the particle in question.
Settling velocity:
Department of Mechanical Process Engineering
Vienna University of Technology Institute of Chemical Engineering
European limit values for fine particle fractions (Environment regulations)
Immission: EU- Council Directive 1999/30 EC, PM10
EU- Council Directive 2008/50EC, PM2.5
Emission: no European limit values
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24 hour mean limit
PM10
Step 1: since 1.1.200550µg/m3
35 exceedences possible per year
Step 2: since 1.1.201050µg/m3
7 exceedences possible per year
Annual mean limit
PM10
Step 1: since1.1.200540µg/m3
Step 2: since1.1.201020µg/m3
EU- Council Directive 99/30 EC, PM10Immission law
Up till now many EU- countries could not reach these limiting values for PM10 extension of the fulfilling deadline: June 2011
→ calls for more intensive separation actions for particle emissions in the future
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EU- Council Directive 2008/50EC, PM2.5Immission law.
Annual mean target
PM2,5
Since 1.1. 201025µg/m3
Annual mean limit
PM2,5
Step 1 since 1.1. 201525µg/m3
Step 2 since 1.1.202020µg/m3
Further more a stricter regulation:
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Staubdeposition im menschlichen Atmungstrakt
A-Dust alveolic Dust 50% smaller than 4 µm
Thoracic-
Dust
Dust 50% smaller than 10 µm
E-Dust inhalable 50% smaller than 100 µm
Working place dust regulations Respirable particle size
EN 481, ISO 778 Workplace (indoor)Inhalable dust fraction: E-dust < 100µmThoracic dust fraction: < 10µmAlveolic dust fraction: A-dust < 4µm
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Particle size range of different kinds of dust
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Particle size distribution of atmospheric dust
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Department of Mechanical Process Engineering
Vienna University of Technology Institute of Chemical Engineering
Generation and sources of dust1) Condensation processes (from gases and
vapours)
2) Dispersion processes (from solid masses, redispersion of already separated dust)
3) Combined processes of 1) and 2)
4) Augmentation of micro organism
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Concerning the sources, particle emission can be divided up into natural and anthropogenic aerosols
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Anthropogenic Aerosolse.g:Combustion processes coal (flyash)Cement productionPetrol and waste combustionIron and steel industryagriculture
Natural aerosolse.g:Soil dustSea spraySmoke from wildfiresBiological particlesVulcano`s
Department of Mechanical Process Engineering
Vienna University of Technology Institute of Chemical Engineering
Dust sampling and measuring methods dust concentration TSP, PM10, PM2,5 (mg/m3)
particle size distribution:
mass (volume) size related Q3, q3 or number sized related Q0, q0
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Immision samplingSuck off from ambient atmosphere Emission sampling
Isokinetic suck-off from a flow channel
Flow situation for different suck-off velocities
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Dust collection devices for emission measurement
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Sampling probe (VDI 2066)
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Often used measurement techniquesHigh Volume sampler:(PM10, PM2.5 PM1) with discontinuous filter sampling, particle mass
1 stage impactor with beta radiation:(PM10, PM2.5 PM1) with continuous filter sampling, particle mass
Cascade impactor:particle size distribution 0.1 to 20µm, discontinuous, particle mass,
Scattered light sensor:particle size distribution 0.25 to 40µm, continuous particle number
Scanning mobility sizer (SMPS): particle size distribution 0.02 to 1µm, continuous, particle number
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High Volume sampler:PM10, PM2.5 PM1 discontinuous measurement
24 hour measuring device
Impactor part
Filter part
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1 stage impactor with beta radiation:PM10, PM2.5, continuous measurement
PM10 or PM2.5 impactor
Moving filterband Beta radiation
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Cascade impactor: mass sized particle size distribution between 0,1 and 20 µm, discontinuous measurement
Aerosol flow In
Clean air out
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ELPICascade impactor with electrical particle charging0,3 - 10 µm
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Continuous measurementParticle number size distribution
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Scattered light sensor: number sized particle size distribution 0.25 – 40 µm, continuous measurement
•
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Scanning mobility particle sizer SMPS: number sized particle size distribution 0.02 – 1 µm, continuous measuring
DMA (Differential mobility analyser)
CPC (Condensation particle counter)
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5 different types of dust separatorsSettling chamber cyclone
Bag house filter
Electrostatic precipitator
Wet scrubber
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Characterisation of dust separators- Fractional separation efficiency T(x)
E: Total separation efficiency
qf: Particle size distribution clean gas
qe: Particle size distribution raw gas
( ))(
)(11)(
xqxqE
xTe
f⋅−−=⇒
- Pressure drop, energy consumption
→ Filtering separator: best separation efficiency
High pressure drop
Goal of further investigations
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Cyclone
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Tangential cyclone
Axial cyclone
Low costLowest separated particle size: 5 – 10 µmGas volume flow influences separation efficiency
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Improvement of the cyclone separation efficiency
Multi cyclone Rotary flow dust collector
Pocket cyclone
Cooled wall cyclone
Application as pre-separator and for hot gas cleaning
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Multi cyclone mostly for pre-separation (coarse particles), downstream bag house filter for fine particle separation
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Electrostatic separator
Plate type
Tube type
Wet electr. Separator (sticky particles)
Electric dust resistance
→ problem for separation efficiency
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„Deutsch“- Equation: relates separation efficiency to the apparatus parameters v, s and L
30
2 s
L
B
gePlattenlän :LdeagselektroNiederschl - rodeSprühelekt Abstand:
1100
s
e vsLw
G
e
⎟⎟⎠
⎞⎜⎜⎝
⎛−⋅= ⋅
⋅
η
v
v: gas velocitywe: migration velocity
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Advantages:Low pressure dropLow maintenanceGood separation efficiency for constant raw gas conditions
Disadvantages:High invest costLarge local wantschanging of the particle resistivity can lower separation efficiency (back corona)
Electrostatic separator
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Wet scrubber
Venturi scrubber
Vortex scrubber
Centrifugal scrubber
Nozzle scrubber
Separation efficiencyPollution is shifted into the liquid
Spray tower
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Addvantages and disadvantages of wet scrubbers
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Droplet separation efficiency
- High relative velocities required between droplet and dust particle→ high energy consumption
- Particle pollution is shifted from the air into the water (water treatment necessary)
-Together with dust removal sorption of gaseous pollutants (SO2, NOx, CO) possible
- separation of sticky and viscous particles possible
Energy consumption
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Wet scrubbing plant
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Filtering separator, 2 kinds: Depth filter: low raw gas dust concentrations (mg/m3)Cleanable filter: high raw gas dust concentrations(g/m3)
Depth filter Cleanable filter
Excellent separation efficiency
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Operation behaviour of cleanable filters
Clean gas concentration
Pressure drop
Time
Important part of the cleanable filter:
FILTER MEDIUM
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Filter medium for cleanable filters: mostly Needle feltsdifferent materials, surface treated (calandered, singed, laminated) to prevent the particle penetration into the depth and to reduce the residual pressure drop
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Surface treated area raw gas side
Clean gas side
hp50,
0
hpi
hp
3
hp
2
hp
1
At
otsurface area of
all sample
s
A1A2A3
Ai
O1
O2O3
Oi
hp
i
PF-layer
.
.
.
.
.
.
.
.
.
Microscopical (transmitting light) and image analysisEvaluation of the porous situation at the surface treated raw gas side and method to optimise the surface treatment of the filter medium
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Image analysis: Conversion of a coloured image into a binary black/white image and elliptic pore approximation
Threshold 130
Threshold: 160to high
Threshold: 115
to low
Elliptic pore approximation
Ap,totOp,totE0dh
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sharp
Determination of the pore depth distribution by an reflecting light microscope
1,0
0,5
0,0hp50,0 hpmax hphp=h2-h1
Q0(hp)
h1
h2
sharp
Pore depth distribution
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Pore depth distribution together with surface porosity E0→
model pore
Q0(hp)0,0 0,5 1,0
hp50,0
hpmax
hp
0,500 * phEH =
H: measure for the dust holding capacity
0
200
400
600
800
1000
1200
1400
1600
-0,5 -0,4 -0,3 -0,2 -0,1 0 0,1 0,2 0,3 0,4 0,5
surface porosity E0 [-]
dept
h of
por
e (h
P) [µ
m]
870
FM7
FM6FM5
FM3
FM1FM2
FM4
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Different fiber materials for filter media
42The cost increase with max. operating temperature
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Hot gas cleaning 500 – 1200 °C
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- heat recovering, dedusting upstream a heat exchanger- avoid corrosion and sticky problems- dry additive reactions are better at high temperatures, protect Nox catalysator- protect gas turbines from dusty gas
Silicium carbid filter candle
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Large sized bag house filterSeveral thousend square meter of filter area
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filter medium must be carefully chosen
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Choice of the filter medium Standard lab test equipment for characterisation
of the operation behaviour of cleanable filter media
Test parameter:
-Residual pressure drop
-Average clean gas concentration
-Dust load of the filter medium
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Different national standard test regulations
Dust feeder
Blow tube
Pressure tankFilter sampleRaw gas channel
Absolute filter
Dust loaded carrier gas
Dust feeder
Blow tube
Pressure tankFilter sampleRaw gas channel
Absolute filter
Dust loaded carrier gas
Absolute filter
Photometer
Raw gas channel
Dust feeder
Back-up filter
Discharge tube
Vakuum pump
Filter sample
Cleaning system
Dust
Absolute filter
Photometer
Raw gas channel
Dust feeder
Back-up filter
Discharge tube
Vakuum pump
Filter sample
Cleaning system
Dust
USA ASTM German VDI3926 Typ I
German VDI 3926 Typ2
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Different national standard test regulations
Dust container
Air inlet
Control valveVakuum
pump
Clean gas ductPressure transducerAbsolut filter
Mass-flowcontroller
Raw gas channelFilter sample
Photometric concentrationmonitor
Dust loaded carrier gas
Pressure tank
Baseplate
Inspection glass
Dust container
Air inlet
Control valveVakuum
pump
Clean gas ductPressure transducerAbsolut filter
Mass-flowcontroller
Raw gas channelFilter sample
Photometric concentrationmonitor
Dust loaded carrier gas
Pressure tank
Baseplate
Inspection glass
German VDI3926 Typ III
JIS Z 8909-1 Japan
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Aging of the filter medium
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30 initial cycles pressure controlled
Aging 10.000 cycles, time controlled cycle time: 5 seconds
30 pressure controlled cycles used for filter media comparison
Measurement of these parameters not at the beginning, but after a so called aged period.
should bring the filter medium in a short time into a state, which is comparable to a long industrial operation time
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Development of an international ISO standard (Draft)Test procedure
Round Robin test which compares different standards shows largedifferences
One of the problems: aging behaviour unclear
Aging: key issueFilter media are usually several years in operation and comparing filter tests should focus also on the filtration behavior along operation time.That means the filter media should be aged in a short time which is comparable to a situation after a long operation time. Tests with very short cycle times (5 – 100 seconds, many cycles up to 10.000)
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Combination of electrostatic charging or an electrostatic separator with a bag house filter
- Electrostatic enhanced filtration
- Hybrid filter: Electrostatic filter (ESP) with downstream bag house filter
- Electrostatic particle agglomeration upstream of a bag house filter
Reason: due to the more stricter air quality regulations for particulates, electrostatic filters can not fulfill these requirements any more
Baghouse filter can fulfill it, but disadvantagous is high pressure drop and premature clogging
Combination can fulfill high separation efficiency also with low pressure drop
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Electrostatic enhancement of cleanable dust filter
Longer cycle times
Lower pressure drop
Lower particle penetration
Riebl et al: TU Cottbus
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Electrostatic enhancementCharged dust particles produce lower dust cake resistance
ESFF/MAX9 Conceptual Design
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Hybrid Filter Combination of ESP and bag house filter
Large dust masses ar separatedin the ESP (90%) which works not very efficiently but cheaply
Remaining dust masses (low conc.) are separated down stream in the bag house filter
-longer cycle and operation times
-Lower pressure drop and pressurised air consumption
-Overall: cost-efficient solution especially by retrofitting an ESP
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Hybrid filter designRetrofit already existing E-filter with a down stream bag filter
Redesign a hybrid filter in one housing
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Hybrid filter
Pre collection in the precipitator section of the filter reduces the dust load and wear on the filter bags.
Less dust on the filter bags results in lower pressure drop, fewer cleaning cycles, and significant compressed air savings.
Reduced pressure loss compared to a traditional fabric filter solution.
Reduced energy consumption compared to a traditional fabric filter solution.
Constant low emissions in spite of varying operational conditions.
Use of existing ESP structure and footprint makes the Hybrid solution cost effective.
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Electrostatic agglomeration upstream the bag house filter
Indigo Agglomerator
Australia
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Thank you very much for your attention