Dust collection by filtration

(Fabric filter / baghouse)

There are three prominent types of baghouses: Reverse

Air (Gas Cleaning), Pulse Air (Compressed Air Cleaning)
and Shaker (Mechanical Cleaning)

Resource:
http://www.neundorfer.com/technical-tips.aspx

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 Reverse-air baghouse
g
The reverse air flow usually lasts from
about 30 seconds to as long as several
minutes

„ Reverse air cleaning

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 Reverse-air baghouse
g

•Reverse-air cleaning is
generally used for
cleaning woven fabrics.
•Cleaning frequency
varies from 30 minutes
to several hours,
depending on the inlet
dust concentration and
the pressure drop of
the baghouse.

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 Dust collection by filtration
(baghouse)
The bag
g cleaning
g byy the pulse
p occurs in
approximately 0.3 to 0.5 seconds
„ Pulse air cleaning

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Reverse-air baghouse
g

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Baghouse

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Baghouse

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Shaker Baghouse (Mechanical
Cleaning)

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 Shaker cleaning baghouses

•Interior filtration
Sh ki should
•Shaking h ld nott be
b usedd
when collecting sticky dusts

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Most pulse-jet baghouses use bag tubes that are 10 to 15 cm in
diameter The length of the bag is usually around 3 to 3.6
diameter. 3 6 m,
m but
can be as long as 6.1 m.
The shaker and reverse-air baghouses use larger bags than the
pulse jet units
pulse-jet units. The bags in shaker and reverse-air
reverse air units are 15
15.2
2 to
45.7 cm in diameter and up to 12.2 m in length

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 Fabric Filter Design Variables

„ Baghouses are designed by considering a number of

variables: pressure dropdrop, filter drag
drag, air-to-cloth
air to cloth ratio,
ratio and
collection efficiency.
„ Pressure drop (∆p) describes the resistance to air flow
across the baghouse. The difference in total pressure at two
points, usually the inlet and outlet
„ Filter drag is the filter resistance across the fabric-dust layer

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Pressure drop

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 Pressure drop

An estimate of pressure drop across shaker and reverse-air

cleaning baghouses

A baghouse
bagho se is normally
no mall operated
ope ated with
ith a pressure
p ess e drop
d op across
ac oss the
unit of 10 to 25cm H2O. But many units operate at less than
15cm H2O.

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 Filtration velocity

Too high filtration velocity => can cause compaction of dust on the bag
resulting in excessive pressure drops
Too low filtration velocity => the baghouse will be larger in size, and
therefore have a higher capital cost.

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 Filtration area

„ Filtration area:
Q 2
S= ,m
vt

Q– volumetric air flow rate, m3/min

vt– filtration
filt ti velocity
l it , m3/m
/ 2.min
i

Material Natural fiber Synthesis Glass fiber

(Woven) filber
vt, m3/m2.ph 0,6-1,2 0,5-1 0,3-0,9

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 Filt ti
Filtration velocity
l it

„ Filtration velocity may depend on filter media,properties of dust

and cleaning mechanism.
„ An example for cement dust, the common filter media should be
worked in range of 1.2 – 1.8 g/m2.min. If the inlet cement dust
concentration is 2g/m3 , filtration velocity is then calculated by
vt = 1,8/2 = 0,9 m3/m2.min

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 Filter drag

The equation for filter drag essentially gives the pressure drop
occurring per unit velocity.

Dust plugging the openings with particles, increasing the drag

rapidly.

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 Collection efficiency

¾Extremely small particles (less than 1 μm in diameter) can

be efficiently collected in a baghouse.
baghouse
¾Baghouse units designed with overall collection
efficiencies of 99.9% (varying particle sizes) are common.
Exhaust air from many baghouses can even be recirculated
back into the plant for heating purposes, as long as the gas
stream is not toxic.

¾Vendors design and size the units strictly on experience.

experience

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Fabric Filter Material

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 Electrostatic precipitators

„ Discharge electrodes: thin wires.

„ Collection electrodes: large plates
(grounded)
„ A negative, high
high-voltage,
voltage, pulsating,
direct current is applied to the
discharge electrode creating a
negative electric field.

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Electrostatic precipitators

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Electrostatic precipitators

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 Electrostatic precipitators

•The electrons bump up to gas

molecules and are captured
captured. This
imparts a negative charge to the
gas molecules, creating negative
gas ions
•The particles are travelling along
in the gas stream and encounter
negative ions moving across their
path.
•Many
M gas ions
i can fit on a
particle, which is pulled to the
collection p
plate

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 Electrostatic precipitators

•Many gas ions can fit on a

particle which is pulled to
particle,
the collection plate
•More and more particles
accumulate, creating a dust
layer.
•This
This dust layer builds until it
is somehow removed
(0.08 to 1.27 cm)

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 Particle Removal

‰Tubes are usually cleaned by

water
t sprays, while
hil plates
l t can be
b
cleaned either by water sprays or
a process called rapping by
sending mechanical impulses, or
vibrations, to the plates.
l d d dust
‰Dislodged d falls
f ll from
f the
h
plates into the hopper
‰Spraying occurs while the ESP is
on-line and is done intermittently to
remove the collected particles
(WESP)
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Electrostatic precipitators

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ESP
 Theoritical calculation
„ Particle migration velocity: n.e.E
v= ,m/ s
3μπd
n- p
particle charge
g (charges)
( g )
e-điện tích điện tử
E-Field Voltage,
g , A/m
/ ε0 - hệ số thẩm thấu điện =
8,854.10-12 C/V.m
D-Particle diameter,m q– điện lượng, Culong
p - hằng số tĩnh điện
μ-viscocity,
μ viscocity, pascal
pascal-seconds
seconds
M t l dust
Metal d t p=3 3
Inert dust (non-conducting
q = n.e = pπε 0 d 2 (Culong ) dust) p = 1,75
Othe s p = 1
Others 1,5
5 – 2,4
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 Theoritical calculation
„ While:
q = n.e = pπε 0 d (Culong )
2

The above equation

q is applicable
pp for particle
p size equal
q to
larger than 1μm, which is charged by inertial collision
between ions and particle

For d≤ 0.1μm charging by ion diffusion q = 108εd

ε = 1,6.10-19 C
 Design variables
However, most ESPs
are designed
g usingga
particle-migration
velocity based on field
experience rather
h than
h
theory
 Collection efficiency
Collection efficiency of the precipitator under ideal conditions
(Deutsch
Deutsch-Anderson
Anderson Equation)
 Collection efficiency
Practical situation:
- Dust reentrainment
-The particle size and, consequently, the migration velocity are not
uniform for all particles
-Gas flow rate is not uniform everywhere across the precipitator
-Particle sneakage (particles escape capture) through the hopper
section
Modifying the Deutsch-Anderson equation. This is accomplished either
by substituting the effective precipitation rate, we, in place of
the migration
g velocity,
y, w,, or byy decreasing g the calculation of
collection efficiency by a factor of k, which is constant (Matts-Ohnfeldt
equation).
 Collection efficiency

The effective precipitation rate (we) refers to the average speed at which
all particles in the entire dust mass move toward the collection electrode.
we, is calculated from field experience

Depending on the standard deviation of the particle size

distribution and other dust properties affecting collection
efficiency
When k = 1.0, the Matts-Ohnfeldt equation is the same as the
Deutsch-Anderson equation
 Tubular ESP

„ Tubular precipitators are generally used for collecting

mists or fogs
fogs, and are most commonly used when collecting
particles that are wet or sticky. Tubular ESPs have been used
to control particulate emissions from sulfuric acid plants, coke
oven byproduct gas cleaning (tar removal), and iron and steel
sinter plants.
Tube diameters typically vary from
0.15 to 0.31 m, with lengths from
1.85 to 4.0m.
 Plate ESP

‰Plate ESPs can have wire, rigid-frame, or

occasionally, plate discharge electrodes.
Di h
Discharge wire
i electrodes
l t d are
approximately 0.13 to 0.38 cm in diameter
‰Collection plates:
For ESPs with wire discharge electrodes, the
plates are usually spaced from 15 to 30 cm
apart,
t and
d 6 andd 12 m high
hi h
For ESPs with rigid-frame or plate discharge
electrodes,, p
plates are typically
yp y spaced
p 30 to Plate
ate ESPs
S sa are
e typ
typically
ca y used for
o
38 cm apart and 8 to 12 m in height. collecting fly ash from industrial
and utility boilers as well as in
manyy other industries including g
cement kilns, glass plants and
pulp and paper mills.
 Single-stage and Two-stage ESPs
„ A single-stage precipitator uses high voltage (50-70kV) to
charge , which are then collected within the same
g the particles,
p
chamber
Single-stage ESPs are widely used in particulate emissions from
boilers and other industrial processes
„ In a two-stage precipitator, particles are charged by low
voltage
l in
i one chamber
h b (ionizing
(i i i stage/particle
/ i l charging),
h i ) and d
then collected in a second chamber (collection stage)
 Two stage ESPs
„ The ionizing stage consists of a series of small, positively
charged wires (12-13kV)
(12 13kV) equally spaced 2 2.5
5 to 5
5.1
1 cm from
parallel grounded tubes or rods.
„ The second stage consists of parallel metal plates less
than 2.5 cm apart. The particles receive a positive charge in
the ionizer stage and are collected at the negative plates in
the second stage.
 Two stage ESPs
Collected smoke or liquids drain by
gravity to a pan located below the
plates, or are sprayed with water
mists or solvents that remove the
particles
ti l and d cause them
th to
t fall
f ll into
i t
the bottom pan.
 T stage
Two t ESPs
ESP
„ Two-stage precipitators were originally designed for air
purification in conjunction
p j with air conditioningg systems
y
(electronic air filters); for the control of finely divided liquid
particles.
„ Controlling solid or sticky materials is usually difficult, and the
collector becomes ineffective for dust loadings greater than
7 35 x 10
7.35 10-3g/m
3 / 3
„ They are used almost exclusively to collect liquid aerosols
discharged from sources such as meat smokehouses
smokehouses, pipepipe-
coating machines, asphalt paper saturators, high speed
grinding
g g machines,, welding g machines,, and metal-coating g
operations.
 C ld id and
Cold-side d Hot-side
H t id ESPs
ESP
„ Cold-side ESPs are used for flue gas having temperatures of
approximately
pp y 204°C or less.
„ Hot-side ESPs are used for flue gas having temperatures
greater than 300°C, located in front of the air preheater

Hot-side ESP

cold-side ESP
 C ld id and
Cold-side d Hot-side
H t id ESPs
ESP
„ Cold-side ESPs are operated at lower temperatures, the volume of
flue gas that is handled is less. Therefore, the overall size of the
unit is smaller, making it less costly.
„ The use of hot-side precipitators help reduce corrosion and hopper
plugging but the overall size of the precipitator is larger making it
plugging,
more costly.Shell and support structure differences in thermal
expansion.
p
„ Fly ash produced from low sulfur coal-fired boilers has high
resistivity making it difficult to collect. High temperatures can lower
resistivity
i ti it => hot-side
h t id ESPs
ESP became
b very popular
l during
d i the
th 1970s.
1970
„ Since the 1980s, operators have generally decided to use cold-side
ESPs along with conditioning agents when burning low sulfur coal coal.
 W ESPs
Wet ESP
„ ESPs can be operated with a wet spray to remove collected
particles. The water flow may
p y be applied
pp continuouslyy or
intermittently to wash the collected particles from the
collection electrodes into a sump (a basin used to collect
liquid))
„ Advantages: avoid rapping reentrainment or with back corona.
„ Wet ESPs are used for industrial applications where the
potential for explosion is high (dust from a closed-hood Basic
Oxygen Furnace in the steel industry) when dust is very sticky,
sticky
corrosive, or has very high resistivity
 Circular-plate
p
wet ESP
„ The circular collection plates
are sprayed
p y with liquidq
continuously
„ Preconditioning sprays located
at the inlet remove some
particulate matter prior to the
charging
h i stage t
„ The casing of wet ESPs is made of
steel o
stee or fiberglass
be g ass a
andd tthe
e
discharge electrodes are made of
carbon steel or special alloys,
depending on the corrosiveness of
the flue gas stream.
Rectangular
fl t l t wett
flat-plate
ESPs
 P i l resistivity
Particle i i i
„ Resistivity is a measure of a particle's resistance to
transferringg charge
g (both
( accepting
p g and giving
g g upp charges),
g ),
significantly affects collection efficiency
„ ESPs work best under normal resistivity conditions.
„ Resistivity is a function of a particle's chemical composition as
well as flue gas operating conditions such as temperature and
moisture.
 Hi h resistivity
High i i i
„ High resistivity can generally be reduced by doing the
following:
g
• Adjusting the temperature
• Increasing moisture content
• Adding conditioning agents to the gas stream
• Increasing the collection surface area
• Using hot-side
hot side precipitators (occasionally)
Conditioning agents: sulfuric acid, ammonia, sodium chloride, and soda
ash.
ash

™Chemical composition of the flue gas stream is important with

regard to the resistivity of the particles to be collected in the
ESP*
Particle
Pa ticle
resistivity
 L
Low resistivity
i i i
„ Particles rapidly lose their charge on arrival at the collection
electrode, and become reentrained in the gas stream
„ Low-resistivity dusts: unburned carbon in fly ash and carbon black.
„ If these conductive particles are coarse, they can be removed
upstream of the precipitator by using a device such as a cyclone.
Baffles are often installed on the collection plates to help eliminate
this precipitation-repulsion
precipitation repulsion phenomenon.
„ Ammonium sulfate compound increases the resistivity of the dust
=> The injection of NH3 has improved the resistivity of fly ash
Industrial application of ESPs