Information Required for the Selection and Performance Evaluation of Wet Scrubbers

The term “wet scrubber” or simply “scrubber,” for the purpose of this report, is intended to include any device using liquid to effect the removal of solid or liquid particles which are entrained in process air or gas streams. This guide is intended to provide information required for the selection and performance evaluation of all types of scrubbers installed for the primary purpose of removing such particulates from any process gas stream. It is not intended to cover scrubbers for the collection of gaseous and/or vapor constituents which involve gas absorption mechanisms.     

Fine Particle Control Using Sulfur Oxide Scrubbers

Compliance with sulfur oxides standards will in many cases result in the installation of scrubbing devices. If these devices operate on an effluent gas stream containing particulate as well as sulfur oxides, simultaneous removal would be expected. Since effective simultaneous removal of particulate matter and sulfur oxides is economically desirable, it is of considerable import to characterize scrubber designs being considered as sulfur oxide absorbers as particulate control devices; especially, for fine particulate control.

Data on the fine particle collection efficiency of sulfur oxides scrubbers at two power generating stations is presented. At the first, a venturi and a turbulent contacting absorber (TCA) both with capacities of 30,000 cfm were tested. At the second, a venturi with 600,000 scfm capacity was tested. Fine particle collection efficiency was determined at three pressure drops for the TCA using a cascade impactor. Results for the TCA show high removal efficiencies. It collected more than 90% of submicron particles when the pressure drop was nearly 10 in. H₂0. The overall particulate removal in the TCA scrubber as determined by modified method 5 or by Brink impactor was greater than 99% when the pressure drop was greater than 6 in. H₂0. For both the venturi scrubber at the Shawnee Steam Plant and that at the Mystic Power Station, the collection efficiency decreased rapidly with decreasing particle size in the fine particle region.     

Relationship of Particulate Control,SO2 Removal,and Waste Management

Results with the EPRI 2.5 MW(e) Integrated Environmental Control Pilot Plant (IECPP) indicate the interrelationship of particulate penetration, SO₂ scrubber operation, waste production, and waste properties. Tests compared a fabric filter/wet scrubber and ESP/wet scrubber, the latter operated to simulate 1979 New Source Performance Standards (NSPS), 1971 NSPS, and pre-NSPS ESP units. Tests were conducted with low-sulfur coal producing a flue gas concentration of400ppm; flue gas spiking could be used to increase SO₂ to 2000 ppm. Scrubber waste was dewatered in a thickener and vacuum belt filter (to 55 percent solids content), and mixed with fly ash. The pilot SO₂ scrubber—when preceded by an ESP and forced to operate in zero-discharge—captured less SO₂ than when preceded by a fabric filter. Also, scrubber operation with the ESP produced a greater quantity of waste with difficult handling characteristics, as compared to operation with the fabric filter. These difficulties occurred with particulate penetration above 0.10 lb/MBtu, which could reduce reagent utilization to 80percent. These results are attributable to inhibited limestone dissolution due to accumulation of an aluminum/fluoride compound. For both lowsulfur and simulated high-sulfur test conditions, allowing wastewater discharge to purge aluminum/fluoride content restored performance to design levels. Particulate control efficiency also affected solid waste physical properties. The fabric filter/wet scrubber produced the lowest solid waste permeability (10^?8 cm/s). ESP operation at 1979 NSPS and pre-1971 NSPS ESPs increased solid waste permeability to 10^?7 and 10^?6 cm/s, respectively. These results are meaningful for SO₂ scrubbers both for new plants and for retrofit to units with pre-NSPS ESPs, and could become significant with the increasing trend to restricted water discharge.     

Performance of Gas-Atomized Spray Scrubbers at High Pressure

A large number of pressurized coal gasification processes being developed propose to use venturi scrubbers for particulate removal at high pressures. Theoretical predictions based on venturi scrubber performance models indicate that particle collection efficiency will decrease severely in these high gas pressure applications.

An exploratory theoretical and experimental program was performed to study the effect of gas pressure on venturi scrubber performance. Experiments were done on a 0.47 m³/s (1000 acfm) pilot scale venturi scrubber. Particle collection performance was determined as a function of scrubber pressure drop for venturi scrubbers operating In the range of 1-10 atm total pressure. Experimental results confirmed that the particle collection efficiency of venturi scrubbers decreases for a given scrubber pressure drop as total gas pressure Is increased. To achieve the same particle collection efficiency, the pressure drop across a venturi scrubber operated at 10 atm Is about 10 times that of the same scrubber operated at 1 atm pressure.     

Atomization and Cloud Behavior In Venturi Scrubbing

The exact collection mechanism of a venturi scrubber has been unknown up to this time. Photographic stop-action techniques and glass venturi scrubbers have made it possible to establish where and how particles are captured and to speculate on possible gas removal possibilities. This report extends the knowledge of pneumatic atomization which is used in gas scrubbing and many other applications by providing further information on cloud-type atomization. Cloud-type atomization which is produced by pneumatic atomization of liquid streams (not drops) results in the formation of liquid droplets which appear to be less than 10 microns in diameter. These droplets coalesce and form clouds which move as single entities. Effective overall cloud diameters are determined to be a function of the velocity of the atomizing gas stream. The effective cloud diameters start at 170 [a and increase as throat gas velocities increase from 150 ft/sec. Throat velocities and liquid inlet nozzle diameters necessary to obtain water clouds of specific effective diameters can be estimated.

These large clouds are efficient impaction targets and stop most of the particulate matter within 0.5 cm from the throat scrubbing liquid inlets. High gas absorption is expected for the clouds of droplets because turbulent gas movement can exist inside and outside the clouds and the 10 μ droplets provide exceptional surface area.     

PCDD/DF concentrations at the inlets and outlets of wet scrubbers in Korean waste incinerators

To further understand the effects of wet scrubbers on PCDD/DF levels, it was measured the concentrations of PCDD/DF, dust, and other gaseous pollutants at both the inlets and the outlets of seven wet scrubbers. As a result, the concentrations of PCDD/DF at the inlets and outlets of the wet scrubbers ranged from 0.2 to 37.4, and 0.8 to 6.0 ng TEQ N m-3, respectively. With the exceptions of wet scrubbers F and G, the PCDD/DF levels decreased by and large in most wet scrubbers. It was thought that their relatively high removal efficiencies were more increased with heavier loads of dust and particle-bound PCDD/DF. On the other hand, it was also surveyed the increase of gaseous PCDD/DF in wet scrubber, where the total level of PCDD/DF was decreased. However, it was not sure whether it had been resulted from the thermal adsorption/desorption phenomenon between packing materials and emission gases or not. At the very least, however, although there still remains an unexplained aspect for the increase of gaseous PCDD/DF, it is clear that wet scrubbers can be sufficiently applied to remove PCDD/DF to a certain extent, if only removal efficiencies for the particle loads are high, and if a significant part of the PCDD/DF at the inlets is particle associated.     

A Study of Primary Sulfate Emissions From a Coal-Fired Boiler with FGD

A study was carried out to investigate the emissions of SO₂ and primary sulfate materials (H₂SO₄ and inorganic particulate matter) from a boiler burning fossil fuel and using a wet-limestone scrubber for SO₂ removal. Experiments were designed to assess the scrubbing efficiency for SO₂ and sulfate, as well as the potential for scrubber liquor reentrainment. The boiler studied was an 820 MW cyclone-fired unit equipped with a wet, limestone scrubber, consisting of eight two-stage venturi-absorber modules designed to treat a flue gas flow rate of 2,760,000 acfm. The boiler fuel was a low-grade sub-bituminous coal with ash and sulfur contents of 25 and 5%, respectively. Multiple-sampling methods were employed concurrently on the inlet and outlet of a candidate absorber module to measure SO₂, total water-soluble sulfate, and free H₂SO₄. Samples were collected during three field experiments from September 1977 through April 1978. The average SO₂ scrubbing efficiency was 76% and was observed to decrease over the 5 day operation/maintenance cycle of the module. The total water-soluble sulfate input to the scrubber amounted to approximately 1% of the total sulfur oxides and was composed of a 5:1 ratio of H₂SO₄ to particulate sulfate. The total sulfate scrubbing efficiency, averaging about 29%, was invariant with respect to SO₂ removal. The sulfate emissions measured in the scrubber exit gas consisted of about 85 % H₂SO₄ as a fine aerosol. Mass emissions of acid and particulate sulfate were calculated as 1730 Ib/hr and 305 Ib/hr, respectively.     

The prediction of PCDD/DF levels in wet scrubbers associated with waste incinerators

Wet scrubber is one of the most conventional types of air pollutant control devices (APCDs), which is specially designed to treat dust and acidic gases in the flue gas simultaneously. In spite of its outstanding ability to control them, however, wet scrubbers have been considered as potential contaminant sources that may increase PCDD/DF concentrations in the flue gas. In this study, we investigated the change of PCDD/DF concentrations at the inlets and outlets of seven wet scrubbers, and compared them with other published data. With a multi-regression analysis of dust concentrations and temperature at the inlets and outlets of given wet scrubbers, we developed an empirical model to understand factors dominating the change of PCDD/DF concentrations. As a result, we confirmed that the changes of PCDD/DF concentrations in wet scrubbers are closely related to their concentrations at the inlets, which would usually be determined by the type of APCDs installed upstream of the wet scrubber.     

Fine Particle Collection Efficiency Related to Pressure Drop,Scrubbant and Particle Properties,and Contact Mechanism

Collection efficiencies are shown for control of fine particles in venturi scrubbers (1) as a function of pressure drop, and (2) as a function of throat area and liquid to gas ratio. A relationship of pressure drop to throat area, gas density, throat velocity, and liquid to gas ratio is given and is used to provide a method for estimating efficiency knowing only these scrubber design parameters. The effect of charged particles and of surface active agents on collection efficiency are discussed briefly.     

Collection of Aerosol Particles by Electrostatic Droplet Spray Scrubbers

Theoretical calculations and experimental measurements show that the collection of small aerosol particles (0.05 to 5 micron diameter range) by water droplets in spray scrubbers can be substantially increased by electrostatically charging the droplets and particles to opposite polarity. Measurements with a 140 acfm two chamber spray scrubber (7 seconds gas residence time) showed an increase in the overall particle collection efficiency from 68.8% tit uncharged conditions to 93.6% at charged conditions, with a dioctyl phthalate aerosol (1.05 μm particle mass mean diameter and 2.59 geometric standard deviation). The collection efficiency for 0.3 μm particles increased from 35 to 87% when charged. During 1973–1974 a 1000 acfm pilot plant electrostatic scrubber was constructed inside a 40 ft trailer for evaluation on controlling particu-late emissions from pulp mill operations (funded by Northwest Pulp and Paper Association). Field tests performed on the particle emissions exhausting from SO₂ absorption towers treating the gases from a magnesium based sulfite recovery boiler have shown particle collection efficiencies ranging from about 60 to 99% by weight, depending on the electrostatic scrubber operating conditions. Energy requirements for the University of Washington electrostatic scrubber are about 0.5 hp/1000 acfm (350 Watts/1000 acfm) including gas pressure drop, water pressure drop, and electrostatic charging of the water spray droplets and the particles.     

Mesoscale behavior study of collector aggregations in a wet dust scrubber

In order to address the bottleneck problem of low fine-particle removal efficiency of self-excited dust scrubbers, this paper is focused on the influence of the intermittent gas-liquid two-phase flow on the mesoscale behavior of collector aggregations. The latter is investigated by the application of high-speed dynamic image technology to the self-excited dust scrubber experimental setup. The real-time-scale monitoring of the dust removal process is provided to clarify its operating mechanism at the mesoscale level. The results obtained show that particulate capturing in self-excited dust scrubber is provided by liquid droplets, liquid films/curtains, bubbles, and their aggregations. Complex spatial and temporal structures are intrinsic to each kind of collector morphology, and these are considered as the major factors controlling the dust removal mechanism of self-excited dust scrubbers. For the specific parameters of gas-liquid two-phase flow under study, the evolution patterns of particular collectors reflect the intrinsic, intermittent, and complex characteristics of the temporal structure. The intermittent initiation of the collector and the air hole formation-collapse cyclic processes provide time and space for the fine dust to escape from being trapped by the collectors. The above mesoscale experimental data provide more insight into the factors reducing the dust removal efficiency of self-excited dust scrubbers.

Implications: This paper focuses on the reconsideration of the capturer aggregations of self-excited dust scrubbers from the mesoscale. Complex structures in time and space scales exist in each kind of capturer morphology. With changes of operating parameters, the morphology and spatial distributions of capturers diversely change. The change of the capturer over time presents remarkable, intermittent, and complex characteristics of the temporal structure.     

Investigation of a Mercury Speciation Technique for Flue Gas Desulfurization Materials

Abstract

Most of the synthetic gypsum generated from wet flue gas desulfurization (FGD) scrubbers is currently being used for wallboard production. Because oxidized mercury is readily captured by the wet FGD scrubber, and coal-fired power plants equipped with wet scrubbers desire to benefit from the partial mercury control that these systems provide, some mercury is likely to be bound in with the FGD gypsum and wallboard. In this study, the feasibility of identifying mercury species in the FGD gypsum and wallboard samples was investigated using a large sample size thermal desorption method. Potential candidates of pure mercury standards including mercuric chloride (HgCl₂), mercurous chloride (Hg₂Cl₂), mercury oxide (HgO), mercury sulfide (HgS), and mercuric sulfate (HgSO₄) were analyzed to compare their results with those obtained from FGD gypsum and dry wallboard samples. Although any of the thermal evolutionary curves obtained from these pure mercury standards did not exactly match with those of the FGD gypsum and wallboard samples, it was identified that Hg₂Cl₂ and HgCl₂ could be candidates. An additional chlorine analysis from the gypsum and wallboard samples indicated that the chlorine concentrations were approximately 2 orders of magnitude higher than the mercury concentrations, suggesting possible chlorine association with mercury.     

Removal characteristics of sulfuric acid aerosols from coal-fired power plants

With increasing attention on sulfuric acid emission, investigations on the removal characteristics of sulfuric acid aerosols by the limestone gypsum wet flue gas desulfurization (WFGD) system and the wet electrostatic precipitator (WESP) were carried out in two coal-fired power plants, and the effects of the WFGD scrubber type and the flue gas characteristics were discussed. The results showed that it was necessary to install the WESP device after desulfurization, as the WFGD system was inefficient to remove sulfuric acid aerosols from the flue gas. The removal efficiency of sulfuric acid aerosols in the WFGD system with double scrubbers ranged from 50% to 65%, which was higher than that with a single scrubber, ranging from 30% to 40%. Furthermore, the removal efficiency of WESP on the sulfuric acid aerosols was from 47.9% to 52.4%. With increased concentrations of SO₃ and particles in the flue gas, the removal efficiencies of the WFGD and the WESP on the sulfuric acid aerosols were increased.

Implications: Investigations on removal of sulfuric acid aerosols by the WFGD and the WESP in the power plants were aimed at the control of sulfuric acid emission. The results showed that the improvement of the WFGD system was beneficial for the reduction of sulfuric acid emission, while the WESP system was essential to control the final sulfuric acid aerosol concentration.     

Tools For Evaluating New Process and Control Plans

The purpose of this paper on industrial plan evaluation is twofold: to present tools which can be used to evaluate quantitatively certain aspects of air pollution control devices, and to point up specifically two areas in which research is urgently needed. These research areas are in removing solid particles after wetting in scrubbers and use of surface active agents in scrubbing gaseous pollutants. Therefore, the body of information presented is directed to engineers in the field of evaluating the air pollution potential of new industrial plants, to scientists involved in determining the parameters and effectiveness of control devices, and to research and development scientists in the field of surfactants.

One tool presented is a chart for measuring the effectiveness of incinerator afterburners and vapor incinerators. The required inputs to the chart are the rate of flue gas flow in standard cubic feet per minute and the auxiliary fuel burner capacity in Btu per hour. The chart yields the flue gas temperature increase which will result, given in degrees F. The second tool presented is a new psychrometric graph for the humidifying and cooling of gases from processes as hot as 3000°F. Inputs into the graph are the temperature of the gases entering the sprays from the hot process and the temperature desired before they enter a control device such as a fabric filter or a scrubber. The chart yield is the amount of water needed in gallons per thousand cubic feet of gas. The only calculation needed is a correction of the hot gas volume to 70°F. Water needed to saturate the gases can be read directly also.     

Effect of Diffusiophoresis and Thermophoresis on the Overall Particle Collection Efficiency of Spray Droplet Scrubbers

The overall particle collection efficiencies of spray scrubbers using monodisperse droplets of 100,500, and 1000 microns diameter were calculated for the cases of evaporating and condensing droplets. The properties of the gas at the inlet to the spray scrubber were maintained constant at 150°F, 100% relative humidity, and 1 atmosphere pressure. At the liquid entrance to the spray scrubber, the water droplet temperature was 50° F for the condensing case and 180° F for the evaporating case. The liquid to gas flow rate ratio for all the calculations was held constant at 4 gal/1000 acf. The gas velocity in the co-current spray tower was 1 ft/sec in the downwind direction. The calculation results show that for the particles in the 0.01 to 10 Mm diameter range, the overall spray scrubber particle collection efficiency is greater with the cooler 50°F water (condensing case) than with the warmer 180°F water (evaporating case). The effect of diffusiophoresis and thermophoresis is noticeable for all the water droplet sizes considered, but is more significant for the larger water droplets. This greater effect for the larger water droplets compared to the smaller droplets is due to the longer existence of the temperature and water vapor concentration gradients between the water droplets and the surrounding gas.     

Product Guide/1982

Abstract

An efficient venturi scrubber system making use of heterogeneous nucleation and condensational growth of particles was designed and tested to remove fine particles from the exhaust of a local scrubber where residual SiH₄ gas was abated and lots of fine SiO₂ particles were generated. In front of the venturi scrubber, normal-temperature fine-water mist mixes with high-temperature exhaust gas to cool it to the saturation temperature, allowing submicron particles to grow into micron sizes. The grown particles are then scrubbed efficiently in the venturi scrubber. Test results show that the present venturi scrubber system is effective for removing submicron particles. For SiO₂ particles greater than 0.1 μm, the removal efficiency is greater than 80–90%, depending on particle concentration. The corresponding pressure drop is relatively low. For example, the pressure drop of the venturi scrubber is ～15.4 ± 2.4 cm H₂O when the liquid-to-gas ratio is 1.50 L/m³. A theoretical calculation has been conducted to simulate particle growth process and the removal efficiency of the venturi scrubber. The theoretical results agree with the experimental data reasonably well when SiO₂ particle diameter is greater than 0.1 μm.     

Spray Charging and Trapping Scrubber for Fugitive Particle Emission Control

The control of fugitive process emissions (FPE) with Spray Charging and Trapping (SCAT) scrubber was evaluated both theoretically and experimentally. The SCAT uses air curtain and/or jets to contain, convey, and divert the FPE into a charged spray scrubber.

Experiments were performed on an 8000 cfm bench-scale spray scrubber to verify the theory and feasibility of collecting fugitive particles with charged water spray. The effects of charge levels on drops and particles, nozzle type, drop size, gas velocity, and liquid/gas ratio on collection efficiency were determined experimentally. The results of the experiments and the comparison between theory and data are presented.

An air curtain was developed for conveying the FPE to the spray scrubber, deflecting the crosswind, and containing hot buoyant plume. The design and air flow field for the air curtain are presented.     

Emissions of Sulfur Trioxide from Coal-Fired Power Plants

Abstract

Emissions of sulfur trioxide (SO₃) are a key component of plume opacity and acid deposition. Consequently, these emissions need to be low enough to not cause opacity violations and acid deposition. Generally, a small fraction of sulfur (S) in coal is converted to SO₃ in coal-fired combustion devices such as electric utility boilers. The emissions of SO₃ from such a boiler depend on coal S content, combustion conditions, flue gas characteristics, and air pollution devices being used. It is well known that the catalyst used in the selective catalytic reduction (SCR) technology for nitrogen oxides control oxidizes a small fraction of sulfur dioxide in the flue gas to SO₃. The extent of this oxidation depends on the catalyst formulation and SCR operating conditions. Gas-phase SO₃ and sulfuric acid, on being quenched in plant equipment (e.g., air preheater and wet scrubber), result in fine acidic mist, which can cause increased plume opacity and undesirable emissions. Recently, such effects have been observed at plants firing high-S coal and equipped with SCR systems and wet scrubbers. This paper investigates the factors that affect acidic mist production in coal-fired electric utility boilers and discusses approaches for mitigating emission of this mist.     

Flux Force/Condensation Scrubbing

Considerations for the engineering design of flux force/condensation (FF/C) scrubbers are reviewed. Fine par-ticulate removal in multiple sieve plate FF/C scrubbers is predicted, using mathematical design models. Results of experimental studies of two multiple sieve plate scrubbers for the removal of submicron particles are given. The published experimental data on FF/C scrubber performance are summarized. A preliminary analysis of the economics of FF/C scrubbers, compared to the conventional high energy scrubbers, defines the most favorable operating conditions for the application of FF/C scrubbers.     

Pilot‐scale field study for ammonia removal from lagoon biogas using an acid wet scrubber

The anaerobic activities in swine slurry storage and treatment generate biogas containing gaseous ammonia component which is a chemical agent that can cause adverse environmental impacts when released to the atmosphere. The aim of this pilot plant study was to remove ammonia from biogas generated in a covered lagoon, using a sulfuric acid wet scrubber. The data showed that, on average, the biogas contained 43.7 ppm of ammonia and its concentration was found to be exponentially related to the air temperature inside the lagoon. When the air temperature rose to 35°C and the biogas ammonia concentration reached 90 ppm, the mass transfer of ammonia/ammonium from the deeper liquid body to the interface between the air and liquid became a limiting factor. The biogas velocity was critical in affecting ammonia removal efficiency of the wet scrubber. A biogas flow velocity of 8 to 12 mm s^?1 was recommended to achieve a removal efficiency of greater than 60%. Stepwise regression revealed that the biogas velocity and air temperature, not the inlet ammonia concentration in biogas, affected the ammonia removal efficiency. Overall, when 73 g L^?1 (or 0.75 M) sulfuric acid solution was used as the scrubber solution, removal efficiencies varied from 0% to 100% with an average of 55% over a 40‐d measurement period. Mass balance calculation based on ammonium–nitrogen concentration in final scrubber liquid showed that about 21.3 g of ammonia was collected from a total volume of 1169 m³ of biogas, while the scrubber solution should still maintain its ammonia absorbing ability until its concentration reaches up to 1 M. These results showed promising use of sulfuric acid wet scrubber for ammonia removal in the digester biogas.