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Air Pollution Control Equipment Selection Guide, Second Edition
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www.crcpress.com
K15953
AIR POLLUTION
Air Pollution Control
Equipment Selection
Guide Second Edition
Kenneth C. Schifftner
Air Pollution Control Equipment Selection Guide
Air Pollution Control Equipment
Selection Guide
Schifftner
Second
Edition
Second Edition
6000 Broken Sound Parkway, NW
Suite 300, Boca Raton, FL 33487
711 Third Avenue
New York, NY 10017
2 Park Square, Milton Park
Abingdon, Oxon OX14 4RN, UK
an informa business
www.crcpress.com
“As an operator and process engineer, I am constantly searching for insights into
what the designer intended, and how it impacts me five years or more later.
This book is an attempt to do that, in a way that lets the operator troubleshoot
control equipment problems without compromising that designer’s intent. More
of this type book is needed—the chasm between design and operation must be
spanned!”
—Rick Ullrich, Wastepro Engineering, Inc., Kennett Square, Pennsylvania
Completely revised and updated, but maintaining the format that made the
first edition so popular, Air Pollution Control Equipment Selection Guide,
Second Edition covers a wide range of equipment and gives a good overview
of the principles and applications. Using the same conversational tone as the
first edition and based on practical experience, the book discusses air pollution
control equipment, including how to choose new equipment and maintain
current equipment.
See What’s New in the Second Edition:
• Updated Typical Applications and Uses sections
• Additional Special Applications chapters covering hybrid systems and others
• Special chapter on Venturi-type scrubbers and recent applications
• Helpful chapter on Systems Diagnostics
As in the previous edition, each chapter contains Device Type, Typical Applications and Uses, Operating Principles, Primary Mechanism Used, Design Basics,
and Operating Suggestions sections. This format allows readers to compare information within those categories. Those who are familiar with the technology,
for example, but want to explore various applications, can easily do so. And those
who are interested in the basics of the design of a particular piece of equipment
can go directly to those sections. The tone remains conversational rather than
scientific and draws upon the real-world experiences of the author and contributing authors to provide practical information that can be immediately applied
to everyday situations.
Air Pollution Control
Equipment Selection
Guide Second Edition
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
Air Pollution Control
Equipment Selection
Guide Second Edition
Kenneth C. Schifftner
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2014 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20130725
International Standard Book Number-13: 978-1-4665-6182-3 (eBook - PDF)
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts
have been made to publish reliable data and information, but the author and publisher cannot assume
responsibility for the validity of all materials or the consequences of their use. The authors and publishers
have attempted to trace the copyright holders of all material reproduced in this publication and apologize to
copyright holders if permission to publish in this form has not been obtained. If any copyright material has
not been acknowledged please write and let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented,
including photocopying, microfilming, and recording, or in any information storage or retrieval system,
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Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
v
© 2010 Taylor & Francis Group, LLC
Contents
Preface.................................................................................................................... xiii
Acknowledgments....................................................................................................xv
About the Author ...................................................................................................xvii
Chapter 1 Air Pollution Control 101 .....................................................................1
1.1 It Is Separation Technology.......................................................1
1.2 Wet Collection of Particulate ....................................................4
1.3 Dry Collection ...........................................................................7
1.4 Gas Absorption..........................................................................8
1.4.1 Concept of “Number of Transfer Units” in
Absorption.................................................................. 10
1.4.2 The Transfer Unit Concept in Gas Absorption .......... 11
Dan Dickeson
1.5 Hybrid Systems........................................................................ 14
Chapter 2 Adsorption Devices............................................................................ 19
2.1 Device Type............................................................................. 19
2.2 Typical Applications and Uses................................................ 19
2.3 Operating Principles................................................................ 19
2.4 Primary Mechanisms Used ..................................................... 21
2.5 Design Basics........................................................................... 21
2.6 Operating Suggestions.............................................................25
Chapter 3 Bioreactors..........................................................................................27
Dr. Robert Richardson
3.1 Device Types ...........................................................................27
3.2 Typical Applications and Uses................................................28
3.3 Operating Principles................................................................30
3.4 Primary Mechanisms Used ..................................................... 32
3.5 Design Basics........................................................................... 33
3.6 Operating Suggestions.............................................................34
3.6.1 Biotrickling Filter Technology ...................................34
3.6.2 Aerobic Digester Technology..................................... 35
3.6.3 Bioscrubber Technology.............................................36
Chapter 4 Dry Cyclone Collectors......................................................................37
4.1 Device Type.............................................................................37
4.2 Typical Applications and Uses................................................37
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© 2010 Taylor & Francis Group, LLC
4.3 Operating Principles................................................................40
4.4 Primary Mechanisms Used ..................................................... 41
4.5 Design Basics........................................................................... 42
4.6 Operating/Application Suggestions......................................... 45
Chapter 5 Electrostatic Precipitators ..................................................................49
Bob Taylor
5.1 Device Type.............................................................................49
5.2 Typical Applications and Uses................................................49
5.3 Operating Principles................................................................ 53
5.4 Primary Mechanisms Used ..................................................... 57
5.5 Creation of Charge .................................................................. 57
5.5.1 Field Charging............................................................ 57
5.5.2 Diffusion Charging .................................................... 57
5.6 Design Basics...........................................................................58
5.7 Resistivity of Dust ...................................................................58
5.8 Operating Suggestions.............................................................60
5.8.1 Air Load/Gas Load Testing........................................60
5.8.2 Alignment...................................................................60
5.8.3 Thermal Expansion .................................................... 61
5.8.4 Air In-Leakage........................................................... 61
5.8.5 Rapping ...................................................................... 61
5.8.6 Insulator Cleaning...................................................... 62
5.8.7 Purge Heater and Ring Heater Systems..................... 62
5.8.8 Process Temperature .................................................. 62
5.8.9 Fuel Changes.............................................................. 62
Chapter 6 Evaporative Coolers ...........................................................................65
Wayne T. Hartshorn
6.1 Device Type.............................................................................65
6.2 Typical Applications and Uses................................................65
6.3 Primary Mechanisms Used .....................................................65
6.4 Design Basics...........................................................................66
6.4.1 Types of Gas Cooling.................................................66
6.4.2 Gas Conditioning........................................................ 67
6.4.3 Basic Sizing................................................................69
6.4.4 All-Important Atomization ........................................72
6.4.5 Case History Example................................................ 76
6.4.6 Cost Considerations....................................................77
6.5 Operating Suggestions............................................................. 78
Contents vii
© 2010 Taylor & Francis Group, LLC
Chapter 7 Fabric Filter Collectors....................................................................... 81
Deny Claffey, Michael Claffey, and Jerry Childress
7.1 Device Type............................................................................. 81
7.2 Typical Applications and Uses................................................ 81
7.3 Operating Principles................................................................83
7.4 Primary Mechanisms Used .....................................................85
7.5 Design Basics...........................................................................86
7.6 Operating Suggestions.............................................................94
Chapter 8 Fiberbed Filters ..................................................................................97
Joe Mayo
8.1 Device Type.............................................................................97
8.2 Typical Applications and Uses................................................97
8.2.1 Acid Mist....................................................................97
8.2.2 Asphalt Processing .....................................................98
8.2.3 Plasticizer/Vinyl/PVC Processing..............................98
8.2.4 Coating/Laminating ...................................................99
8.2.5 Electronics..................................................................99
8.2.6 Textile Processing.......................................................99
8.2.7 Metalworking ........................................................... 101
8.2.8 Lube Oil Vents and Reservoirs ................................ 101
8.2.9 Incinerator Emissions............................................... 101
8.2.10 Internal Combustion Engine Crankcase Vents ........ 103
8.2.11 Precious Metal Recovery ......................................... 103
8.2.12 Vacuum Pumps......................................................... 103
8.3 Operating Principles.............................................................. 104
8.4 Primary Mechanisms Used ................................................... 105
8.5 Design Basics......................................................................... 105
8.6 Operating/Application Suggestions....................................... 107
8.6.1 Filter Cleaning.......................................................... 107
8.6.2 Fiberbed Filter Life .................................................. 107
8.6.3 Fire Protection if the Contaminant Is
Combustible ........................................................ 108
Chapter 9 Filament (Mesh Pad) Scrubbers....................................................... 109
9.1 Device Type........................................................................... 109
9.2 Typical Applications.............................................................. 109
9.3 Operating Principles.............................................................. 111
9.4 Primary Mechanisms Used ................................................... 111
9.5 Design Basics......................................................................... 111
9.6 Operating Suggestions........................................................... 114
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© 2010 Taylor & Francis Group, LLC
Chapter 10 Fluidized Bed Scrubbers.................................................................. 115
10.1 Device Type........................................................................... 115
10.2 Typical Applications and Uses.............................................. 115
10.3 Operating Principles.............................................................. 116
10.4 Primary Mechanisms Used ................................................... 121
10.5 Design Basics......................................................................... 121
10.6 Operating Suggestions........................................................... 122
Chapter 11 Mechanically Aided Scrubbers........................................................ 125
11.1 Device Type...........................................................................125
11.2 Typical Applications and Uses.............................................. 125
11.3 Operating Principles..............................................................126
11.4 Primary Mechanisms Used ................................................... 128
11.5 Design Basics......................................................................... 129
11.6 Operating Suggestions........................................................... 129
Chapter 12 Packed Towers.................................................................................. 131
12.1 Device Type........................................................................... 131
12.2 Typical Applications and Uses.............................................. 131
12.3 Operating Principles.............................................................. 132
12.4 Primary Mechanisms Used ................................................... 136
12.5 Design Basics......................................................................... 136
12.5.1 Counterflow.............................................................. 136
12.5.2 Crossflow.................................................................. 139
12.6 Operating Suggestions........................................................... 139
Chapter 13 Settling Chambers............................................................................ 141
13.1 Device Type........................................................................... 141
13.2 Typical Applications and Uses.............................................. 141
13.3 Operating Principles.............................................................. 141
13.4 Primary Mechanisms Used ................................................... 142
13.5 Design Basics......................................................................... 143
13.6 Operating/Application Suggestions....................................... 144
Chapter 14 Spray Towers/Scrubbers................................................................... 145
14.1 Device Type........................................................................... 145
14.2 Typical Applications and Uses.............................................. 145
14.3 Operating Principles.............................................................. 145
14.4 Primary Mechanisms Used ................................................... 147
14.5 Design Basics......................................................................... 149
14.6 Operating Suggestions........................................................... 150
Contents ix
© 2010 Taylor & Francis Group, LLC
Chapter 15 Thermal Nitrogen Oxide (NOx) Control .......................................... 153
Joseph Colannino
15.1 Device Type........................................................................... 153
15.2 Typical Applications and Uses: Combustion Sources........... 153
15.3 Operating Principles.............................................................. 153
15.4 Primary Mechanisms Used ................................................... 154
15.5 Design Basics......................................................................... 154
15.5.1 Different Forms of NOx............................................ 154
15.5.2 NOx Measurement Units........................................... 154
15.5.3 Thermal NOx ............................................................ 155
15.5.4 Fuel-Bound NOx ....................................................... 157
15.6 Thermal-NOx Control Strategies........................................... 159
15.7 Dilution Strategies................................................................. 159
15.8 Staging Strategies.................................................................. 160
15.9 Postcombustion Strategies..................................................... 160
15.10 Operating/Application Suggestions....................................... 162
Chapter 16 Thermal Oxidizers........................................................................... 163
Dan Banks
16.1 Device Type........................................................................... 163
16.2 Typical Applications.............................................................. 163
16.3 Operating Principles.............................................................. 163
16.4 Primary Mechanisms Used ................................................... 164
16.5 Design Basics......................................................................... 166
16.6 Operating Suggestions........................................................... 171
Chapter 17 Tray Scrubbers ................................................................................. 173
17.1 Device Type........................................................................... 173
17.2 Typical Applications and Uses.............................................. 173
17.3 Operating Principles.............................................................. 173
17.4 Primary Mechanism Used..................................................... 177
17.5 Design Basics......................................................................... 177
17.6 Operating Suggestions........................................................... 178
Chapter 18 Vane Type Scrubbers........................................................................ 181
18.1 Device Type........................................................................... 181
18.2 Typical Applications.............................................................. 181
18.3 Operating Principles.............................................................. 181
18.4 Primary Mechanisms Used ................................................... 182
18.5 Design Basics......................................................................... 185
18.6 Operating Suggestions........................................................... 186
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© 2010 Taylor & Francis Group, LLC
Chapter 19 Venturi Scrubbers............................................................................. 189
19.1 Device Type........................................................................... 189
19.2 Typical Applications.............................................................. 189
19.3 Operating Principles.............................................................. 190
19.4 Primary Mechanisms Used ................................................... 191
19.5 Design Basics......................................................................... 191
19.6 Operating/Application Suggestions....................................... 199
Chapter 20 Wet Electrostatic Precipitators......................................................... 201
Wayne T. Hartshorn
20.1 Device Type........................................................................... 201
20.2 Typical Applications and Uses.............................................. 201
20.3 Primary Mechanisms Used ...................................................202
20.4 Design Basics.........................................................................203
20.5 Types of Wet Precipitators.....................................................207
20.5.1 Configuration............................................................207
20.5.2 Arrangement.............................................................208
20.5.3 Irrigation Method .....................................................208
20.6 Selecting a Wet Electrostatic Precipitator............................. 211
20.7 Operating Suggestions........................................................... 214
Chapter 21 Special Applications: Venturi “Scrubbers” as Evaporators............. 217
21.1 Device Type........................................................................... 217
21.2 Typical Applications.............................................................. 217
21.3 Operating Principles.............................................................. 218
21.4 Primary Mechanism Used..................................................... 218
21.5 Design Basics......................................................................... 218
21.6 Operating Suggestions...........................................................222
Chapter 22 Energy Recovery ..............................................................................223
22.1 Device Type...........................................................................223
22.2 Typical Applications and Uses..............................................223
22.3 Operating Principles..............................................................225
22.4 Primary Mechanism Used.....................................................227
22.5 Design Basics.........................................................................227
22.6 Operating Suggestions...........................................................228
Chapter 23 Multitechnique Equipment for Gasification (Syngas) ...................... 231
23.1 Device Type(s)....................................................................... 231
23.2 Typical Applications and Uses.............................................. 232
23.2.1 Starved-Air Gasification........................................... 232
23.2.2 Plasma Destruction................................................... 233
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23.2.3 Reformer Gasification ..............................................234
23.3 Operating Principles..............................................................234
23.4 Primary Mechanisms Used ................................................... 235
23.5 Design Basics......................................................................... 235
23.6 Operating Suggestions........................................................... 237
Chapter 24 System Diagnostics and Testing....................................................... 239
24.1 Tools ...................................................................................... 239
24.2 Isolate and Correct the Problem............................................ 241
24.2.1 Define the Problem................................................... 241
24.2.2 Inspect the Scrubber and/or System.........................242
24.2.3 Baseline the System..................................................242
24.2.4 Search for a Detailed Solution to the Problem.........243
24.2.4.1 Gas Cleaning Device ................................243
24.2.4.2 Liquid Circuit Problems ...........................245
24.2.4.3 Instrumentation Issues..............................247
24.2.4.4 Gas Moving Device ..................................248
24.2.4.5 Gas Discharge Device...............................250
24.2.5 Fix the Problem........................................................ 252
Appendix A: Additional Selected Reading ........................................................ 253
Appendix B: List of Photo Contributors............................................................259
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© 2010 Taylor & Francis Group, LLC
Preface
It is gratifying as an author to find that the product of my effort is being put to good
use. In my travels, I’ve seen copies of the first edition of the Air Pollution Control
Equipment Selection Guide in a wide variety of libraries and on numerous bookshelves. Some are in the corporate libraries of consulting firms, some at colleges and
universities, and others in private collections. Some of these copies have dog-eared
pages indicating that the reader must have found something of interest and may want
to return. That is why the first edition book was produced. It was intended to be a
valuable reference resource over time.
For the second edition, the operative word is listening. Readers liked the general format of the first edition and that format is retained herein. The Device Type,
Typical Applications and Uses, Operating Principles, Primary Mechanism Used,
Design Basics, and Operating Suggestions format for each chapter remains. The use
of this format for each chapter allows the reader to compare within those categories.
If you are familiar with the technology, for example, but want to explore various
applications, you can easily do so. If you are interested in the basics of the design
of a particular piece of equipment, you can go to those sections. The tone remains
conversational rather than scientific.
When asked what additional information they would like to see, readers of the
first edition mentioned a number of things, which, I hope, have been addressed in
this second edition. For example, they asked for an expansion of the “Air Pollution
Control 101” chapter (maybe it should now be “Air Pollution Control 102”?) to
include comments about dealing with gases that are far afield from ambient air.
These conditions occur quite often today regarding gasification systems wherein the
gas stream may contain lower molecular weight gases under much higher pressures
than ambient conditions.
For the chapter on cyclone collectors, additional information is provided regarding large diameter, product recovery type cyclones that are used on rotary dryers
and the like.
Where appropriate, additional up-to-date information is provided under the
Typical Applications and Uses sections. For example, the “Fabric Filter Collectors”
chapter was enlarged and refined to include spray dryer fabric filter collector combination systems for acid gas and mercury control. Photos of some existing installations are provided.
A group of chapters (21–23) is now included featuring Special Applications. The
hybrid type systems noted here may combine various wet or dry scrubbing techniques or form a team of various technologies to solve a specific problem wherein
one technology alone would be insufficient. For other challenges, the use of a specific technique is modified. As an example, sometimes Venturi scrubbers are used as
evaporators rather than particulate control devices. Their proper design, however, is
required to minimize any particulate generation resulting in air pollution. A special
chapter on Venturi evaporators has therefore been added. Coupled with a packed or
xiv Preface
© 2010 Taylor & Francis Group, LLC
tray tower device, that Venturi evaporator “hybrid” can also recover the evaporated
water, or recover heat, or both.
It seems that some owners of the first edition already have air pollution control
equipment and want to improve its performance. Initially, they used the book to
explore alternative technologies to replace the problem device, but given the cost
of replacement, their focus shifted to how to get the most out of their existing
hardware. So, in response, a special chapter was added to address that request.
That new chapter, “System Diagnostics and Testing” (Chapter 24), goes over basic
problem diagnosis for both wet- and dry-type gas cleaning equipment and provides
some remedial suggestions. Therefore, the reader may want to use the second edition as a resource to select new hardware or to modify and keep what they have. If
you are thinking of salvaging your existing gas cleaning system, you may want to
read the last chapter first!
Much of the information contained herein derives from the past nearly five
decades in the air pollution control industry. The industry is dynamic and challenging. To provide improved content, I turned to the most reliable source, colleagues
and friends met during those decades. I am profoundly grateful for the information,
pictures, and other content supplied by these contributors and hope that the reader is
pleased with the result.