Вы находитесь на странице: 1из 7

See

discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/305441375

Wet Scrubbers Design of Spray Tower to


Control Air Pollutants

Article January 2016

CITATIONS READS

0 299

1 author:

Dr. akshey Bhargava


Kalol Institute of Technology & Research Centre
17 PUBLICATIONS 4 CITATIONS

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Senior Professor, Global Institute of Engineering and Technology, Hyderabad View project

All content following this page was uploaded by Dr. akshey Bhargava on 25 July 2016.

The user has requested enhancement of the downloaded file. All in-text references underlined in blue are added to the original document
and are linked to publications on ResearchGate, letting you access and read them immediately.
International Journal of Environmental Planning and Development
Vol. 2: Issue 1
www.journalspub.com

Wet Scrubbers Design of Spray Tower to Control Air


Pollutants
Akshey Bhargava*
Department of Civil Engineering, Global Institute of Engineering and Technology, Hyderabad, India

Abstract
Wet scrubbers are compatible and effective air pollution control devices to arrest particulate
matters and polluting gases coming out of industrial processes as air polluting emissions.
There are various types of wet scrubbers but the present paper deals with Spray Towers and
its design. The author of the present paper designed the Spray Tower for a 100 TPD cement
plant based on Vertical Shaft Technology (VSK) after monitoring the air emissions in regard
to designed parameters under variable conditions on a time scale. The efficiency of the
designed Spray Tower has been to the tune of more than 95 percent.

Keywords: particulate matter control, spray tower, wet scrubbers


*
Corresponding Author
E-mail: draksheyb@gmail.com

BACKGROUND Particulate/dust scrubbers


Wet scrubbers are effective air pollution Sulfuric acid scrubbers
control devices for removing particles
and/or gases from industrial exhaust Particulate Scrubbers/Dust Scrubbers
streams. A wet scrubber operates by The concept of wet particulate/dust
introducing the dirty gas stream with a scrubbers is pretty straightforward. A
scrubbing liquid typically water. liquid usually water is injected into the
Particulate or gases are collected in the waste gas stream. The liquid droplets
scrubbing liquid. Wet scrubbers are impact and entrain particulates from the
generally the most appropriate air waste gas stream and collecting them in
pollution control device for collecting both the sump for blow down. The treated air
particulate and gas in a single system. stream is discharged through the exhaust
Pollution systems offer a variety of wet stack.[25]
scrubber systems specifically designed for
process application. Many important The scrubbers design will be impacted by
operating variables are considered when a wide range of variables such as:
evaluating the size and type of scrubber Nature of the particulate/dust to be
for any specific application.[1] removed
Particulate size distribution, initial
Types of Wet Scrubbers pollutant loading/concentration in the
Chemical scrubbers/gas scrubbers waste stream and whether it Is
Particulate scrubbers/venturi flammable or combustible
scrubbers Required removal efficiency
Ammonia scrubbers Temperature and flow rate of the
Chlorine scrubbers waste stream

IJEPD (2016) 6873 JournalsPub 2016. All Rights Reserved Page 68


Design of Spray Tower to Control Air Pollutants Bhargava

Scrubber location, indoors or outside different means of ensuring a relative


velocity between water droplets and the
Due to these and other challenges, finding gas to be cleaned. In all cases the cleaning
the right kind of wet dust scrubber can be mechanism involves attachment of
a challenge. particulates to the droplets. The droplets
are then collected and drained to a sump.
Many industries in the chemical and Scrubbers in common use are[6,7]:
building materials industries may be
required to reduce the amount of (i) Spray chamber or spray tower
particulate they release into the (ii) Centrifugal or cyclone scrubber
environment. These requirements typically (iii)Orifice or self-induced spray
depend on application and locality. In all (iv) Ventury scrubber
scrubbers droplets of the scrubbing media
are formed, generally much larger than the Various Types of Scrubbers and Their
particles to be collected. In most cases, Applications
scrubbing media is water, occasionally a Scrubbers can also be classified as low
different substance is used Different types and high energy. Such a classification
of scrubbing devices employ different along with their applications is reflected in
means of forming water droplets and Table 1.

Table 1. Scrubbers with Their Applications.


Sr.
Low energy scrubbers Application
no.
Coarse particulate matter removal and moderate removal efficiency for gaseous
1. Spray scrubbers
pollutants.
2. Wet cyclonic scrubbers Moderate/high particulate matter removal upto 5 microns
Moderate to high removal for scrubbers coarse particulate upto 3 microns &
3. Vertical baffled scrubbers
gaseous pollutants
Horizontal baffled spray
4. High efficiency for gaseous pollutants.
scrubbers
5. Packed bed scrubbers High efficiency for gaseous pollutants.

Sr. no. High energy scrubbers Application


Very high efficiency for fine particulate with partial removal of gaseous
1. Venturi scrubbers
pollutants.
2. Ejector scrubbers Very high efficiency for coarse particulate and gaseous pollutants
3. High efficiency wet filters Very high efficiency for fine particulate matter soluble in scrubbing liquid
Cleanable high efficiency air
4. For removal of aerosols P205, SO3, etc.
filter
5. High efficiency air filter For removal of sticky and oily particulates, aerosols and mists.

SPRAY TOWER as pre-formed spray scrubbers, since the


Spray towers are very simple, low-energy liquid is formed into droplets prior to
wet scrubbers. In these scrubbers, the contact with the gas stream. The size of
particulate-laden gas stream is introduced the droplets generated by the spray
into a chamber where it comes into contact nozzles is controlled to maximize liquid-
particle contact and, consequently,
with liquid droplets generated by spray scrubber collection efficiency. The
nozzles. These scrubbers are also known common types of spray chambers are

IJEPD (2016) 6873 JournalsPub 2016. All Rights Reserved Page 69


International Journal of Environmental Planning and Development
Vol. 2: Issue 1
www.journalspub.com

spray towers and cyclonic chambers. cyclonic motion inside the chamber. This
Spray towers are cylindrical or rectangular motion contributes to higher gas
chambers that can be installed vertically or velocities, more effective particle and
horizontally. In vertical spray towers, the droplet separation, and higher collection
gas stream flows up through the chamber efficiency. Tangential inlet or turning
and encounters several sets of spray vanes are common means of inducing
nozzles producing liquid droplets. A de- cyclonic motion.
mister at the top of the spray tower
removes liquid droplets and wetted PM The scrubbing liquid, usually water for
from the exiting gas stream. Scrubbing particulate matter removal, is sprayed into
liquid and wetted PM also drain from the the chamber from a series of nozzles
bottom of the tower in the form of slurry. located at the top chamber while the air-
Horizontal spray chambers operate in the particle mixture enters the bottom of
same manner, except for the fact that the chamber and flows upward, encountering
gas flows horizontally through the device. the droplets formed from the sprays which
A typical spray tower is shown in Figure fall to the bottom by gravity. The droplets
1.[810] remove the particles by scrubbing action,
the resulting slurry so formed is collected
A cyclonic spray chamber is similar to a at the bottom and sent for treatment for
spray tower with one major difference. removal of collected particles and treated
The gas stream is introduced to produce water is recirculated.

Fig. 1. Typical Spray Tower.

Design of Spray Tower spray chamber having regard to Reynolds


The design of Spray Tower is generally number, drop formation rates, shape of
oriented towards collection efficiency of tower, time for impaction and diffusion
the system which inter-alia include along with other parameters, the details of
designed upward velocity of air in the which are reflected as under:

IJEPD (2016) 6873 JournalsPub 2016. All Rights Reserved Page 70


Design of Spray Tower to Control Air Pollutants Bhargava

Collection efficiency of spray tower, using Reynolds number is given by


following: Red = 1.020*107*D3/2
L = length of tower Since the drop falls with velocity Vd
Dsc = diameter of tower where
Va = velocity of upward air Vd = V Va (particle travel upward
Vd = velocity of dropping droplets with velocity Va)
V = relative velocity between drops Time period for impaction, diffusion
and air becomes :
Red = Reynolds number = 10 < Red > L/Va + L/Vd, and n becomes:
700 n = (Nd* * D2/4* Asc)*(L/Va + L/Vd)
D = diameter of droplet Total drop formation rate is related to
d = density of droplet mass flow rate of spray fluid as:
= density of air Nd = 6* ms/* d3* d
= viscosity of air n becomes
n = no of droplets encountered by a N = (1.5*ms*L
group of particles d*D)*(1/Q+1/(Asc*(VVa))
Nd = rate of drop formation in number If spray chamber is circular, then
per second Asc = D2sc/4
Asc = area of tower
Upward velocity of air in chamber: Collection efficiency for a single droplet =
Va = Q/Asc, which must not exceed d, is defined as ratio of no. of particles
drop velocity Vd to prevent air from collected to no. of particles initially
carrying drops out of the top of contained in the volume swept through by
chamber the droplet.To predict the behavior of the
F = Force acting on the drop particles as they flow around and into the
droplet, a particle of given diameter and
F = *d*D3*g/6 = 5.135* d*D3
density will strike the droplet if it lies
If spray liquid is water,
initially within a certain distance y1 of the
F = 5135 D3 axis of motion of the droplet. If it lies
If Reynolds number for the drop
away from axis than this, it will pass by
motion is between 10 and 700:
the droplet and not collected.[11]
V =
(4.8/*D)*((447*2)+(*d*D3*g/6)) The collection efficiency of the
20.4* individual droplet due to interception and
For standard air as gas and water as inertial impaction combined di can be
spray liquid, the above equation defined as the ratio of the area of circle
becomes: having radius y1 to the projected area of
V = (178.3/D)*(0.7814*1010+D3) the droplet. This ratio is modified by an
1.520*103/D attachment coefficient .
The Reynolds number becomes:
Red = V*D/v = From above, efficiency is defined as:
6 3 10
11.50*10 *(D +0.7814*10 ) 2
98.06 di = (* y * )/(* D2/4) = 4* *
1
If Reynolds number is greater than 2
700, y /D2, and
1
V = (2.4/D)*(* d*D3*g/6*) = = (5/72)*(p* d2* Vt* C/* D)
5.44*(d*D/) Now considering boundary layer
For standard air and water conditions,
V = 158 D Red > 700

IJEPD (2016) 6873 JournalsPub 2016. All Rights Reserved Page 71


International Journal of Environmental Planning and Development
Vol. 2: Issue 1
www.journalspub.com

2
= Density of water droplet
= 8.811* *(v/V *D) *((y / ) D
di 2 2
4 D= Water droplet = 1 kg/m3
1/6*(y / ) ) D = water droplet size = 2 mm
2 2
when y < msc = flow of water = 0.01 m3/s
2 2 C= Cunnigatum correction factor =1.0
and
= Attachment coefficient =1.0
7.342* *v/V *D, when y =
di = 2 2 ps = Initial pressure drop = 200 N/m2
and V= viscosity of fluid = 1.55105 m2/s
di = 7.342* *v/V *D+(2*

)*(y2/D) Spray Tower Design
2/D)*(3+6*y2/D+4*(y2/D)2), when y2 Asc = Dc2/4
> 2 = 3.14 22/4
= 3.14 m2
= combined efficiency of all the
droplet Va = Q/Asc
= 6.94/3.14
1 (1 di)n
=2.21 m/s
Power requirement
Red = 1.020 107 (D)3/2
W= 9.807 (dxQsxAscxL) + QPs
= 1.020 107 (0.002) 3/2
Asc Q/V
= 912
where Ps = Pressure drop of water
2 V = Red V/D
droplets (N/m ) = 912 x 1.55 105
0.002
DESIGN OF SPRAY TOWER FOR V =7.02
VSK BASED CEMENT PLANT Vd = V Va
An effort has been made in the present = 7.06 2.21
paper by the Author to design a Spray = 4.85 m/s
Tower for a 100 TPD (Tonne per day) n = 1.5 m L [1/Q + 1/Asc (V
capacity cement plant based on Vertical s

Shaft Kiln Technology (VSK) located in Vd)]


Rajasthan. d x D
= 1.5 0.01 5 [1/6.94 + 1/3.14(7.06
The monitoring was carried out in respect 4.85)]
of relevant designed parameters under all 1 0.002
the operating conditions on a time scale = 10.8
and the representative observed values are = 7.342 (v/v D)
given here under: = 7.342 1 (1.55 105/7.06
0.002)
Parameters Observed = 0.243
n
Volume of gases = 25,000 m3/hour= = 1 (1 di)
6.94 m3/s 10.8

Temperatures of gases = 100C = 1 (1 0.243)


Inlet SPM concentration = 2000 =0.95%
mg/Nm3
Density of particle = 1500 kg/m3 Inlet Concentration = 2000 mg/Nm3
Parameters Assumed Efficiency of spray tower estimated = 95%
Outlet concentration = 0.05 2000
Length of tower = 5 m 3
Diameter of tower = 2 m = 100 mg/Nm

IJEPD (2016) 6873 JournalsPub 2016. All Rights Reserved Page 72


Design of Spray Tower to Control Air Pollutants Bhargava

Which is much below the standard of 250 4. Sun J., Liu B.Y.H., McMurry P.H., et
mg/m3 al. A method to increase control
Hence safe efficiencies of wet scrubbers for
Now Power requirement = W submicron particles and particulate
W= 9.807 xQsxAscx2 + Q Ps metals, J Air Waste Manag Assoc.
Asc Q/V 1994; 44: 2p.
= 9.087 1500 0.01 3.14 5 + 6.69 5. Control Techniques for Particulate
200 Emissions from Stationary Sources
3.14 6.94/7.06 Volume 1 (EPA - 450/3-81-005a,
= 2458 watts NTIS PB83-127498). U.S.
Environmental Protection Agency,
CONCLUSIONS Office of Air Quality Planning and
An effort has been made by the author to Standards. Research Triangle Park,
design Spray Tower as wet scrubbing North Carolina. September 1982.
device to control particulate matter 6. U.S. Environmental Protection
emitted from a 100 TPD capacity cement Agency. Compilation of Air Pollutant
plant based on Vertical Shaft Kiln Emission Factors (AP-42). Vol I., 5th
Technology (VSK) located in the State of Edn. Research Triangle Park, North
Rajasthan. Since the particulate matter Carolina: U.S. Environmental
from such VSK plants are having Protection Agency; 1995.
moistures, the selection of Spray Tower 7. Lerner B.J. Particulate wet scrubbing:
was considered suitable for the control of the efficiency scam, In: The
particulate matters. Hence, the Spray Proceedings of the A&WMA
Tower was designed which gives the Specialty Conference on "Particulate
efficiency to the tune of 95 percent by Matter; Health and Regulatory Issues
reducing the initial concentration of 2000 (VIP- 49). April 46, 1995,
mg/Nm3 to outlet concentration of 100 Pittsburgh, Pennsylvania, A&WMA,
mg/Nm3 of particulate matter after the Pittsburgh, Pennsylvania, 1995.
Spray Tower. This has resulted in bringing 8. Woodard K., U.S. Environmental
the pollutants level well below the Protection Agency. Source Category
prescribed limit of 250 mg/Nm3 and hence Emission Reductions with Particulate
found safe. Such Spray Towers can be Matter and Precursor Control
designed and installed in VSK based mini Techniques., Research Triangle Park,
cement plants to control particulate matter North Carolina (AQSSD/IPSG),
with in the permissible norms. under Work Assignment II-16 (EPA
Contract No. 68-03-0034),
REFERENCES Evaluation of Fine Particulate
1. Cooper C.D., Alley F.C. Air Pollution Matter Control. September 30, 1996.
Control: A Design Approach. 2nd 9. Vatavuk W.M. Estimating Costs of
Edn. Prospect Heights, Illinois: Air Pollution Control. Chelsea,
Waveland Press; 1994. Michigan: Lewis Publishers; 1990.
2. The Scrubber Manual (Revised). 10. Vatavuk W.M., Neveril R.B. Factors
Northbrook, Illinois: The McIlvaine for estimating capital and operating
Company; 1995. costs, Chem Eng. 1980, 15762p.
3. Perry R.H., Green D.W. Perry's 11. Schifftner K.C., Hesketh H.E. Wet
Chemical Engineers' Handbook. 6th Scrubbers: A Practical Handbook.
Edn. New York: McGraw- Hill Chelsea, Michigan: Lewis Publishers,
Publishing Company, Inc.; 1984. 1986.

IJEPD (2016) 6873 JournalsPub 2016. All Rights Reserved Page 73

View publication stats

Вам также может понравиться