An efficient venturi scrubber system to remove submicron particles in exhaust gas

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 0.1microm, 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 approximately 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 microm.     

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.     

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.     

Evaluating the performance of a turbulent wet scrubber for scrubbing particulate matter

A turbulent wet scrubber was designed and developed to scrub particulate matter (PM) at micrometer and submicrometer levels from the effluent gas stream of an industrial coal furnace. Experiments were conducted to estimate the particle removal efficiency of the turbulent scrubber with different gas flow rates and liquid heads above the nozzle. Particles larger than 1 µm were removed very efficiently, at nearly 100%, depending upon the flow rate, the concentration of the dust-laden air stream, and the water level in the reservoir. Particles smaller than 1 µm were also removed to a greater extent at higher gas flow rates and for greater liquid heads. Pressure-drop studies were also carried out to estimate the energy consumed by the scrubber for the entire range of particle sizes distributed in the carrier gas. A maximum pressure drop of 217 mm H₂O was observed for a liquid head of 36 cm and a gas flow rate of 7 m³/min. The number of transfer units (NTU) analysis for the efficiencies achieved by the turbulent scrubber over the range of particles also reveals that the contacting power achieved by the scrubber is better except for smaller particles. The turbulent scrubber is more competent for scrubbing particulate matter, in particular PM_2.5, than other higher energy or conventional scrubbers, and is comparable to other wet scrubbers of its kind for the amount of energy spent.

Implications: The evaluation of the turbulent scrubber is done to add a novel scrubber in the list of wet scrubbers for industrial applications, yet simple in design, easy to operate, with better compactness, and with high efficiencies at lower energy consumption. Hence the turbulent scrubber can be used to combat particulate from industrial gaseous effluents and also has a scope to absorb gaseous pollutants if the gases are soluble in the medium used for particles capture.     

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.     

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.     

Specifying Venturi Scrubber Throat Length for Effective Particle Capture at Minimum Pressure Loss Penalty

A simplified equation for specifying the optimum minimum length for commercial venturi scrubber throats is presented in this paper. This theoretical correlation is derived using an optimum velocity ratio (velocity of collector droplet at end of venturi throat to velocity of gas in throat) and is a function of throat gas velocity and liquid to gas ratio. This velocity ratio establishes the minimum throat length and is based on available literature data. Predicted venturi scrubber particle collection for throats specified by this procedure compare favorably with reported commercial venturi collection efficiencies and with modeled venturi efficiencies over the practical range of venturi scrubber operation.     

Investigation of aerosol and gas emissions from a coal-fired power plant under various operating conditions

The concentrations of fine particles and selected gas pollutants in the flue gas entering the stack were measured under several common operation modes in an operating coal power plant producing electricity. Particle size distributions in a diameter range from 10 nm to 20 μm were measured by a scanning mobility particle sizer (SMPS), and the flue gas temperature and concentrations of CO₂ and SO₂ were monitored by a continuous emission monitoring system (CEMS). During the test campaign, five plant operating modes were studied: soot blowing, bypass of flue-gas desulfurization (FGD), reheat burner operating at 0% (turned off), 27%, and 42% (normal condition) of its full capacity. For wet and dry aerosols, the measured mode sizes were both around 40 nm, but remarkable differences were observed in the number concentrations (#/cm³, count per square centimeter). A prototype photoionizer enhanced electrostatic precipitator (ESP) showed improved removal efficiency of wet particles at voltages above +11.0 kV. Soot blowing and FGD bypass both increased the total particle number concentration in the flue gas. The temperature was slightly increased by the FGD bypass mode and varied significantly as the rating of reheat burner changed. The variations of CO₂ and SO₂ emissions showed correlations with the trend of total particle number concentration possibly due to the transitions between gas and particle phases. The results are useful in developing coal-fired power plant operation strategies to control fine particle emissions and developing amine-based CO₂ capture technologies without operating and environmental concerns associated with volatile amine emissions.

Implications: The measurement of the fine particle size distributions in the exhaust gas under several common operating conditions of a coal-fired power plant revealed different response relations between aerosol number concentration and the operating condition. A photo-ionizer enhanced ESP was demonstrated to capture fine particles with higher efficiency compared to conventional ESPs, and the removal efficiency increased with the applied voltage. The characteristic information of aerosols and main gaseous pollutants in the exhaust gas is extremely important for developing and deploying CO₂ scrubbers, whose amine emissions and operating effectiveness depends greatly on the upstream concentrations of fine particles, SO₂, from the power plant.     

Wet Electrostatic Precipitators for Control of Submicron Particles

The application of wet electrostatic precipitators is rapidly gaining popularity. The emission regulations are becoming more and more stringent and they are being enforced. The emphasis on removal of fine particles and organic liquid droplets in the submicron range is increasing. In order to meet the required outlet loadings and opacities, the pressure drop that has to be applied across a conventional scrubber has increased exponentially. The wet electrostatic precipitator is emerging as an economic alternative by virtue of its very low power consumption and its potential for removal of submicron particles with efficiencies in the high nineties. Several applications of the wet electrostatic precipitator will be reviewed in this paper.     

The Capture of Heavy Metals from Incineration Using a Spray Dryer Integrated with a Fabric Filter Using Various Additives

ABSTRACT

This study investigated the effects of feedstock additives [polyvinyl chloride (PVC) and NaCl] and spray dryer additives (SiO₂, CaCl₂, NaHCO₃) on heavy metal and fly ash removal efficiencies, and on particle size distribution of heavy metals. A spray dryer with an integrated fabric filter was used as an air pollution control device (APCD). Removal efficiencies for fly ash and heavy metals were greater than 95 and 90%, respectively. When additives of PVC or NaCl were used, the concentration of heavy metals distributed in fly ash apparently varied when the particle diameter was <1 μm. Although the effects of the additives SiO₂, CaCl₂, and NaHCO₃ on the elemental size distribution of Cr were insignificant, these additives did slightly increase concentrations of Cd, Zn, and Pb partitioning in coarser particles (>1μm).     

Gas Chromatographic Analysis of Incinerator Effluents

Comparative gas cleaning performance of a pilot-scale venturi scrubber with throat dimensions of 6 in. wide × 1 2 in. long × 1 2 in. deep was obtained for the following three methods of water injection: a system of spray nozzles located along each short side of the throat (Figure 2a); a continuous slot located immediately above the nozzles, along each short side of the throat (Figure 2b); and a weir located 2 ft above the spray nozzles along long side of the throat (Figure 2c). For each method of water injection the gas cleaning performance, as a function of the pressure drop, was measured by two tests: absorption of SO₂ and collection efficiency for particles of methylene blue of controlled size.     

Engineering Design of Fine Particle Scrubbers

A concise, quantitative picture of the state of the art of particle scrubbing is presented in the form of performance prediction methods. A new relationship between the particle diameter collected at 50% efficiency and scrubber pressure drop for several of the most common scrubber types is a design tool of great utility. Scrubber capability for the collection of submicron particles by diffusion is described in a graph for several scrubber types.     

Minnesota Power’s Operating Experience with Integrated Particulate and SO2 Scrubbing

Minnesota Power currently has in commercial operation a 500 MW gas cleaning system consisting of a venturi particulate scrubber, integrated with a spray tower SO₂ absorber. The system was designed to achieve 99.7% particulate removal and 90% SO₂ removal based upon burning a 2.8 % sulfur coal.

Initially the concept of using a venturi for wet particulate collection was selected based upon a significant cost saving of $25 million compared to dry particulate collection devices. Subsequently, the Interaction of particulate collection with SO₂ removal provided additional operating cost benefits. Prior to start-up of the commercial system, a pilot plant was used to evaluate various modes of operation. Results showed that alkali contained in the fly ash removed with the venturi was sufficient to meet the alkali requirement for SO₂ removal.

Clay Boswell Station Unit No. 4 was started up during March 1980. Since initial start-up the system has exhibited almost 100% availability. EPA compliance testing has confirmed that the system Is meeting its emission standards. The unit is operating with fly ash as the only source of alkali. Since commercial operation started, no external alkali has been purchased.

This paper will discuss the design details of the system and performance of the commercial system.     

New High-Efficiency Mist Collector

The recently developed York Type P acid mist scrubber collects phosphoric acid mists and other very fine liquid particulates with very high efficiency with moderate pressure drop and high throughput. The collector consists of a single vessel containing two stainless steel wire mesh contactors. The collector converts submicron size acid mist into larger liquid particles which are collected and separated from the gas stream before being discharged from the collector. The first commercial unit started operation in July 1964, and four additional units have since been installed. Collection efficiency is 99.9+% at a pressure drop of 35-40 in W.G. The scrubber is compact and has no moving parts. Collected acid drains by gravity to a receiving tank. Experimental development work is described and design parameters such as efficiency, gas velocity, and pressure drop are discussed.     

PM2.5 chemical source profiles for vehicle exhaust, vegetative burning, geological material, and coal burning in Northwestern Colorado during 1995

PM_2.5 (particles with aerodynamic diameters less than 2.5 μm) chemical source profiles applicable to speciated emissions inventories and receptor model source apportionment are reported for geological material, motor vehicle exhaust, residential coal (RCC) and wood combustion (RWC), forest fires, geothermal hot springs; and coal-fired power generation units from northwestern Colorado during 1995. Fuels and combustion conditions are similar to those of other communities of the inland western US. Coal-fired power station profiles differed substantially between different units using similar coals, with the major difference being lack of selenium in emissions from the only unit that was equipped with a dry limestone sulfur dioxide (SO₂) scrubber. SO₂ abundances relative to fine particle mass emissions in power plant emissions were seven to nine times higher than hydrogen sulfide (H₂S) abundances from geothermal springs, and one to two orders of magnitude higher than SO₂ abundances in RCC emissions, implying that the SO₂ abundance is an important marker for primary particle contributions of non-aged coal-fired power station contributions. The sum of organic and elemental carbon ranged from 1% to 10% of fine particle mass in coal-fired power plant emissions, from 5% to 10% in geological material, >50% in forest fire emissions, >60% in RWC emissions, and >95% in RCC and vehicle exhaust emissions. Water-soluble potassium (K⁺) was most abundant in vegetative burning profiles. K⁺/K ratios ranged from 0.1 in geological material profiles to 0.9 in vegetative burning emissions, confirming previous observations that soluble potassium is a good marker for vegetative burning.     

Mathematical Modeling of SO2 Absorption in a Venturi Scrubber

Abstract

A three-dimensional mathematical model was used to predict the removal efficiency of a venturi scrubber for SO₂ absorption into a water and alkaline solution. In order to obtain better results, nonuniform droplet concentration distribution was considered. The results of the model with nonuniform droplet concentration distribution are compared with several sets of experimental data, as well as with prediction data of a mathematical model with uniform droplet concentration distribution. Without exception, all comparisons indicated that including nonuniformity of droplet concentration distribution in the model will significantly improve the agreement between the experimental data and predicted values.     

An Analysis of Visual Range in the Eastern United States Under Different Meteorological Regimes

ABSTRACT

The issue of fine particle (PM₂₅) exposures and their potential health effects is a focus of scientific research because of the recently promulgated National Ambient Air Quality Standard for PM_{2 5}. Before final implementation, the health and exposure basis for the standard will be reviewed by the U.S. Environmental Protection Agency within the next five years. As part of this process, it is necessary to understand total particle exposure issues and to determine the relative importance of the origin of PM_{2 5} exposure in various micro-environments. The results presented in this study examine emissions of fine particles from a previously uncharacterized indoor source: the residential vacuum cleaner. Eleven standard vacuum cleaners were tested for the emission rate of fine particles by their individual motors and for their efficiency in collecting laboratory-generated fine particles. An aerosol generator was used to introduce fine potassium chloride (KC1) particles into the vacuum cleaner inlet for the collection efficiency tests. Measurements of the motor emissions, which include carbon, and the KCl aerosol were made using a continuous HIAC/Royco 5130A light-scattering particle detector. All tests were conducted in a metal chamber specifically designed to completely contain the vacuum cleaner and operate it in a stationary position. For the tested vacuum cleaners, fine particle motor emissions ranged from 9.6 x 10⁴ to 3.34 x 10⁸ particles/min, which were estimated to be 0.028 to 176 mg/min for mass emissions, respectively. The vast majority of particles released were in the range of 0.3-0.5 mm in diameter. The lowest particle emission rate was obtained for a vacuum cleaner that had a high efficiency (HEPA) filter placed after the vacuum cleaner bag and the motor within a sealed exhaust system. This vacuum cleaner removed the KC1particles that escaped the vacuum cleaner bag and the particles emitted by the motor. Results obtained for the KC1 collection efficiency tests show >99% of the fine particles were captured by the two vacuum cleaners that used a HEPA filter. A series of tests conducted on two vacuum cleaners found that the motors also emitted ultra-fine particles above 0.01 mm in diameter at rates of greater than 10⁸ ultra-fine particles/CF of air. The model that had the best collection efficiency for fine particles also reduced the ultra-fine particle emissions by a factor of 1 x 10³.     

Continuous Monitoring of Ultrafine,Fine, and Coarse Particles in a Residence for 18 Months in 1999-2000

Abstract

Continuous monitors were employed for 18 months in an occupied townhouse to measure ultrafine, fine, and coarse particles; air change rates; wind speed and direction; temperature; and relative humidity (RH). A main objective was to document short-term and long-term variation in indoor air concentrations of size-resolved particles (0.01-20 μm) caused by (1) diurnal and seasonal variation of outdoor air concentrations and meteorological variables, (2) indoor sources such as cooking and using candles, and (3) activities affecting air change rates such as opening windows and using fans. A second objective was to test and compare available instruments for their suitability in providing real-time estimates of particle levels and ancillary variables.

Despite different measuring principles, the instruments employed in this study agreed reasonably well for particles less than 10 μm in diameter. The three instruments measuring fine and coarse particles (aerodynamic diameter between 0.3 and 20 μm) agreed to within 30% in their overall estimates of total volume. Two of these instruments employed optical scattering, and the third used an aerodynamic acceleration principle. However, several lines of evidence indicated that the instrument employing aerodynamic acceleration overestimated concentrations for particle diameters greater than 10 μm. A fourth instrument measuring ultrafine and accumulation-mode particles (0.01-1 μm) was operated with two different inlets providing somewhat different particle size ranges. The two inlets agreed in the ultrafine region (<0.1 μm) but diverged increasingly for larger particles (up to 0.445 μm).

Indoor sources affecting ultrafine particle concentrations were observed 22% of the time, and sources affecting fine and coarse particle concentrations were observed 12 and 15% of the time, respectively. When an indoor source was operating, particle concentrations for different sizes ranged from 2 to 20 times the average concentrations when no indoor source was apparent. Indoor sources, such as cooking with natural gas, and simple physical activities, such as walking, accounted for a majority (50-90%) of the ultrafine and coarse particle concentrations, whereas outdoor sources were more important for accumulation-mode particles between 0.1 and 1 um in diameter. Averaged for the entire year and including no periods when indoor sources were apparent, the number distribution was bimodal, with a peak at ~10 nm (possibly smaller), a shallow minimum at ~14 nm, and a second broad peak at ~68 nm. The volume distribution was also bimodal, with a broad peak at ~200 nm, a minimum at ~1.2 μm, and then an upward slope again through the remaining size fractions.

A database was created on a 5-min averaging time basis. It contains more than 90,000 measurements by two of the instruments and approximately 30,000 by the two optical scattering instruments. About 4500 hour-long average air change rates were also calculated throughout the year using a dedicated gas chromatograph with electron capture detection (GC/ECD). At high air change rates [>0.8 air changes per hour (hr^?1)], particle concentrations were either elevated (when no source was present) or depressed (when an indoor source was operating) by factors of up to 2 compared with low air change rates.     

Size and Composition Distributions of Particulate Matter Emissions: Part 1—Light-Duty Gasoline Vehicles

Abstract

Size-resolved particulate matter (PM) emitted from light-duty gasoline vehicles (LDGVs) was characterized using filter-based samplers, cascade impactors, and scanning mobility particle size measurements in the summer 2002. Thirty LDGVs, with different engine and emissions control technologies (model years 1965–2003; odometer readings 1264–207,104 mi), were tested on a chassis dynamometer using the federal test procedure (FTP), the unified cycle (UC), and the correction cycle (CC). LDGV PM emissions were strongly correlated with vehicle age and emissions control technology. The oldest models had average ultrafine PM_0.1 (0.056- to 0.1-μm aerodynamic diameter) and fine PM_1.8 (≤1.8-μm aerodynamic diame ter) emission rates of 9.6 mg/km and 213 mg/km, respectively. The newest vehicles had PM_0.1 and PM_1.8 emis sions of 51 μg/km and 371 μg/km, respectively. Light duty trucks and sport utility vehicles had PM_0.1 and PM_1.8 emissions nearly double the corresponding emission rates from passenger cars. Higher PM emissions were associated with cold starts and hard accelerations. The FTP driving cycle produced the lowest emissions, followed by the UC and the CC. PM mass distributions peaked between 0.1-and 0.18-μm particle diameter for all vehicles except those emitting visible smoke, which peaked between 0.18 and 0.32 μm. The majority of the PM was composed of carbonaceous material, with only trace amounts of water-soluble ions. Elemental carbon (EC) and organic matter (OM) had similar size distributions, but the EC/OM ratio in LDGV exhaust particles was a strong function of the adopted emissions control technology and of vehicle maintenance. Exhaust from LDGV classes with lower PM emissions generally had higher EC/OM ratios. LDGVs adopting newer technologies were characterized by the highest EC/OM ratios, whereas OM dominated PM emissions from older vehicles. Driving cycles with cold starts and hard accelerations produced higher EC/OM ratios in ultrafine particles.     

Measurement of Fine Particles in Diesel Emissions Using a Real-Time Aerosol Monitor

Abstract

A real-time monitoring methodology to determine diesel fine particles in diesel emissions has been evaluated. The range of particle size captured by the monitor was ～0.1 μm to 1 μm. DustTrak real-time monitors were connected to the dilution tunnel of the vehicle exhaust to measure the emissions during the vehicle tests under both dynamic and steady-state driving conditions, and concentration data were recorded every 5 sec. Test variation of the real-time monitoring among different test days was similar to that measured by traditional filter-based gravi-metric method, whereas the repeatability of the monitor data within the same-day tests was better than that of gravimetric method. Correlations between the two methods were established for different fuels tested on a single light duty vehicle. When the emissions from the reference fuel was used to convert the monitor’s response to diesel fuels, the levels determined by the real-time monitor were consistent with those measured by gravimetric method among different fuels tested. Use of the real-time monitor could provide information on the levels of fine particles that is more relevant to the public health than the total particles.