Reducing pressure drop in a baghouse using flow distributors.

The pressure drop of ladder vanes in a baghouse could be reduced by decreasing the vane number and adjusting the inclined angle of the vane. Two types of flow distributors were utilized to test pressure drop caused by the structure of a baghouse. The pressure drops were measured by an inclined manometer under various filtration velocities. The purpose of this study is to understand the improvement effect of pressure drop saving for the traditional ladder vanes. Experimental results showed that the pressure drop of the Vane 3-1 configuration (flow distributor with three vanes perpendicular to the inlet flow) was higher than that of the Empty configuration (without flow distributors). The Vane 3-1 configuration could not reduce the pressure drop because of the barrier effect. By reducing the number and adjusting the angle of the vanes, the barrier effect was decreased, and the pressure drop of the Vane 2-1 configuration was much lower than that of the Vane 3-1 configuration. The largest difference in pressure drop between Vane 2-1 and Vane 3-1 was 1.702 cm w.g. at a filtration velocity of 4.17 cm/sec and, in terms of percentage, is 18.52% corresponding to a filtration velocity of 2.25 cm/sec. The improvement effect on the pressure drop saving for Vane 3-1 was significant.     

Effect of Flow Distributors on Uniformity of Velocity Profile in a Baghouse

Abstract

In recent years, the utility industry has turned to bag-houses as an alternative technology for particulate emission control from pulverized-coal–fired power plants. One of the more significant issues is to improve poor gas distribution that causes bag failures in baghouse operation. Bag failures during operation are almost impossible to prevent, but proper flow design can help in their prevention. This study investigated vertical velocity profiles below the bags in a baghouse (the hopper region) to determine whether flow could be improved with the installation of flow distributors in the hopper region. Three types of flow distributors were used to improve flow distribution and were compared with the original baghouse without flow distributors. Velocity profiles were measured by a hot-wire anemometer at an inlet velocity of 18 m/sec. Uniformity of flow distribution was calculated by the uniformity value U for the velocity profile of each flow distributor. Experimental results showed that the velocity profile of the empty configuration (without flow distributors) was poor because the uniformity value was 2.048. The uniformity values of type 1 (flow distributor with three vertical vanes), type 2 (flow distributor with one vertical and one inclined vane), and type 3 (flow distributor with two inclined vanes) configurations were reduced to 1.051, 0.617, and 0.526, respectively. These results indicate that the flow distributors designed in this study made significant improvements in the velocity profile of a baghouse, with the type 3 configuration having the best performance.     

Effect of flow distributors on uniformity of velocity profile in a baghouse

In recent years, the utility industry has turned to baghouses as an alternative technology for particulate emission control from pulverized-coal-fired power plants. One of the more significant issues is to improve poor gas distribution that causes bag failures in baghouse operation. Bag failures during operation are almost impossible to prevent, but proper flow design can help in their prevention. This study investigated vertical velocity profiles below the bags in a baghouse (the hopper region) to determine whether flow could be improved with the installation of flow distributors in the hopper region. Three types of flow distributors were used to improve flow distribution and were compared with the original baghouse without flow distributors. Velocity profiles were measured by a hot-wire anemometer at an inlet velocity of 18 m/sec. Uniformity of flow distribution was calculated by the uniformity value U for the velocity profile of each flow distributor. Experimental results showed that the velocity profile of the empty configuration (without flow distributors) was poor because the uniformity value was 2.048. The uniformity values of type 1 (flow distributor with three vertical vanes), type 2 (flow distributor with one vertical and one inclined vane), and type 3 (flow distributor with two inclined vanes) configurations were reduced to 1.051, 0.617, and 0.526, respectively. These results indicate that the flow distributors designed in this study made significant improvements in the velocity profile of a baghouse, with the type 3 configuration having the best performance.     

Electrostatic Stimulation of Fabric Filtration

The concept of electrostatic stimulation of fabric filtration (ESFF) has been investigated at pilot scale. The pilot unit consisted of a conventional baghouse in parallel with an ESFF baghouse, allowing direct comparison. All results reported in this paper are for pulse-cleaned bags in which the electric field was maintained parallel to the fabric surface. The performance of the ESFF baghouse has been superior to the parallel conventional baghouse by several measures. The ESFF baghouse demonstrated: (1) a reduced rate of pressure drop increase during a filtration cycle, (2) lower residual pressure drop, (3) stable operation at higher face velocities, and (4) improved particle removal efficiency. These benefits can be obtained with only minor modifications to conventional pulse-jet hardware and at low electrical power consumption. The indicated ability to operate at increased face velocities with only modest expenditure for electrical hardware leads to very favorable economic projections.     

Advanced Electrostatic Stimulation of Fabric Filtration

In advanced electrostatic stimulation of fabric filtration (AESFF), a high voltage electrode is placed coaxially inside a filter bag to establish an electric field between the electrode and the bag surface. The electric field alters the dust deposition pattern within the bag, yielding a much lower pressure drop than that found in a conventional bag. Pilot plant results show that AESFF bags can operate with a rate of pressure loss that is 70 percent below that for conventional bags. The presence of the electric field also affects the aging characteristics of the AESFF bags. On the average, the AESFF bags had residual drags that were 10 percent below those of conventional bags. The results show that AESFF baghouses can yield the same pressure drop performance as conventional baghouses while operating at much higher air-to-cloth ratios. An economic analysis evaluated the capital, operating, and maintenance costs for electric utility plants ranging from 200 to 1,000 MW. For AESFF baghouses the capital cost was found to be 25 to 48 percent below that of a conventional baghouse. A lifetime cost analysis predicts a net present value for an AESFF baghouse that is 10 to 30 percent below that of a conventional baghouse.     

Liquid Entrainment from a Mobile Bed Scrubber

Liquid entrainment rate and drop size distribution were measured in the exhaust gas stream from a mobile bed scrubber. The pilot plant scrubber was 46 cm (18 in.) square and was packed with 3.8 cm (1.5 In.) diameter hollow polyethylene spheres to a static depth of 25 cm (10 in.). Entrainment flow rate depends on both gas and liquid rates. At a liquid/gas ratio of 6.7 l/m³ (50 gal/Mcf) and a superficial gas velocity of 2.6 m/sec (8.5 ft/sec) the entrainment flow rate was 0.0064 l/m³ (0.05 gal/Mcf) and at 3.75 m/sec (12.3 ft/sec) it was 0.031 l/m³ (0.23 gal/Mcf). The mass median drop diameter was about 400 nm at a liquid/gas ratio of 6.7 l/m³. The drop size distribution appears to be bimodal. Dye impregnated paper and cascade impactor techniques were used to measure drop size.     

Status and Future of Baghouses in the Utility Industry

Abstract

The cumulative years of service of baghouses in the electric utility industry have doubled since the last industrywide review of their operating performance. We have gathered information from all 102 operating baghouses to develop an updated record of how this technology continues to serve the electric utility industry. In general, baghouse performance has met or exceeded the expectations for controlling emissions. There are, however, wide ranges of pressure drop and bag life performance. Most operators report a long-term trend of increasing pressure drop. The life expectancy of filter bags averages 7.5 years, with more than 20% of the population achieving more than 10 years of bag life. Factors such as coal and ash properties certainly affect baghouse operation, but another reason for variations in bag life is the lack of an optimized protocol for controlling the long-term buildup of residual dustcake. We conclude that many baghouses could operate with lower pressure drop and longer bag life by optimizing the cleaning system. Dustcake weight or drag are better indicators of performance than pressure drop and should be used to develop an optimum baghouse operating protocol.     

Improving Baghouse Performance at the Monticello Generating Station

At the Monticello station, operated by the Texas Utilities Generating Company, lignite coal obtained locally in Titus and Hopkins Counties fuels each of the three units. Units 1 and 2 are identical 575-MW Combustion Engineering (CE) boilers, each of which discharges its effluent to a 36- compartment shake/deflate cleaned baghouse paralleled with four electrostatic precipitators (ESP). Unit 3 is a larger boiler and is followed by an ESP and a scrubber. The Unit 1 and 2 baghouses were designed to clean 80 percent of the flue gas. Since startup, these baghouses have regularly experienced flange-to-flange pressure drops in excess of 10 in. H₂O, with large opacity spikes caused by ash bleeding through the bags after compartment cleanings. Because of higher-than-expected pressure drop, the baghouses receive only about 45-50 percent of the flue gas. Analysis has shown the Monticello lignite ash significantly differs from most other coal ashes. Testing has shown that the Monticello ash is not filtered effectively by many "standard" bag materials. However, this testing indicates that there are fabrics that show promise of eliminating the ash bleedthrough with little pressure drop penalty. Testing has also shown that injection of low concentrations (10-15 ppm) of ammonia (NH₃) into the flue gas significantly decreases ash bleedthrough, so that with NH₃ injection "standard" bag materials may perform adequately. Currently, fullcompartment testing of four fabrics, with and without NH₃ injection, is under way at the Unit 1 baghouse. The research conducted at the Monticello station is reviewed in this paper and the encouraging results from the full-compartment tests are presented.     

The role of pressure drop and flow redistribution on modeling mercury control using sorbent injection in baghouse filters

A mathematical model based on simple cake filtration theory was coupled to a previously developed two-stage mathematical model for mercury (Hg) removal using powdered activated carbon injection upstream of a baghouse filter. Values of the average permeability of the filter cake and the filter resistance extracted from the model were 4.4 x 10(-13) m2 and 2.5 x 10(-4) m(-1), respectively. The flow is redistributed during partial cleaning of the filter, with flows higher across the newly cleaned filter section. The calculated average Hg removal efficiency from the baghouse is lower because of the high mass flux of Hg exiting the filter in the newly cleaned section. The model shows that calculated average Hg removal is affected by permeability, filter resistance, fraction of the baghouse cleaned, and cleaning interval.     

Prediction of particulate loading in exhaust from fabric filter baghouses with one or more failed bags

Loss of filtration efficiency in a fabric filter baghouse is typically caused by bag failure, in one form or another. The degree of such failure can be as minor as a pinhole leak or as major as a fully involved baghouse fire. In some cases, local air pollution regulations or federal hazardous waste laws may require estimation of the total quantity of particulate matter released to the environment as a result of such failures. In this paper, a technique is presented for computing the dust loading in the baghouse exhaust when one or more bags have failed. The algorithm developed is shown to be an improvement over a previously published result, which requires empirical knowledge of the variation in baghouse pressure differential with bag failures. An example calculation is presented for a baghouse equipped with 200 bags. The prediction shows that a small percentage of failed bags can cause a relatively large proportion of the gas flow to bypass the active bags, which, in turn, leads to high outlet dust loading and low overall collection efficiency from the baghouse.     

Prediction of Particulate Loading in Exhaust from Fabric Filter Baghouses with One or More Failed Bags

Abstract

Loss of filtration efficiency in a fabric filter baghouse is typically caused by bag failure, in one form or another. The degree of such failure can be as minor as a pinhole leak or as major as a fully involved baghouse fire. In some cases, local air pollution regulations or federal hazardous waste laws may require estimation of the total quantity of particulate matter released to the environment as a result of such failures. In this paper, a technique is presented for computing the dust loading in the baghouse exhaust when one or more bags have failed. The algorithm developed is shown to be an improvement over a previously published result, which requires empirical knowledge of the variation in baghouse pressure differential with bag failures. An example calculation is presented for a bag-house equipped with 200 bags. The prediction shows that a small percentage of failed bags can cause a relatively large proportion of the gas flow to bypass the active bags, which, in turn, leads to high outlet dust loading and low overall collection efficiency from the baghouse.     

去除污泥中重金属铬的生物淋滤反应器设计与应用

用微生物方法去除污泥中重金属（生物淋滤法）是近年来发展的新技术，探索工程化的条件有重要的应用价值。设计了一套容积为1m^3的生物淋滤反应器，由生物淋滤池、搅拌器、曝气器和空气压缩机等构成。其中，搅拌叶轮由平叶桨和斜叶桨组合而成。利用制革污泥进行了半连续的生物淋滤试验，结果表明，在反应器中污泥与菌体和营养物质能充分混匀，经过2-5d的处理，污泥pH持续下降到2．0以下，污泥中铬的溶出率达90％-99．5％。     

Determination of Baghouse Performance from Coal and Ash Properties: Part I

Baghouse performance at utility coal-fired power plants is determined by baghouse design, operating procedures, and the characteristics of the ash that is collected as a dustcake on the fabric filter. The Electric Power Research Institute has conducted laboratory research to identify the fundamental properties of dustcake ash that influence baghouse performance. A database was assembled including measured characteristics of dustcake ash and data describing operating parameters and performance of full-scale and pilot-scale baghouses. Semi-empirical models were developed that describe the effects of particle morphology, particle size, ash cohesivity and ash chemistry on filtering pressure drop and particulate emissions. Cohesivity was identified as the primary ash characteristic affecting baghouse performance. Predictions of performance can be based on physical or chemical characterizations of the ash to be filtered. Part II of this article will discuss the effects of ash and coal chemistry, and baghouse design and operation on performance.     

滤袋数目对翼形上进风袋式除尘器内流场影响的数值模拟研究

针对实际运行过程中,袋式除尘器滤袋使用寿命短,压力损失过大的问题,本文以翼形上进风袋式除尘器为研究对象,采用CFD(computational fluid dynamics)技术模拟分析不同滤袋数(分别为92、88、84、80、76和72)时袋式除尘器内气流分布和压力损失规律。主要考察了流量分配系数、最大流量不均幅值、气流迹线、滤袋表面速度分布与压降等指标。结果表明,滤袋数为76个时,气流分布最为均匀,各滤袋负载均衡;相同过滤速度下,装置的压降随滤袋数目的增加而上升,即压降大小顺序为9288847672;与72个滤袋相比,76个滤袋的可用过滤面积更大。综合考虑,袋式除尘器的最优滤袋数目为76个。模拟结果为袋式除尘器的设计和优化提供了依据。     

去除污泥中重金属铬的生物淋滤反应器设计与应用

用微生物方法去除污泥中重金属(生物淋滤法)是近年来发展的新技术,探索工程化的条件有重要的应用价值。设计了一套容积为1 m3的生物淋滤反应器,由生物淋滤池、搅拌器、曝气器和空气压缩机等构成。其中,搅拌叶轮由平叶桨和斜叶桨组合而成。利用制革污泥进行了半连续的生物淋滤试验,结果表明,在反应器中污泥与菌体和营养物质能充分混匀,经过2~5 d的处理,污泥pH持续下降到2.0以下,污泥中铬的溶出率达90%~99.5%。     

Note On The Collection of Lint Fly by Wet Impingement

A combined water scrubber-impinger was used to control lint cleaner effluent from machine-stripped short staple (11/16-13/16 in.) cotton because of its high efficiency and low pressure drop. The 8 × 4 × 4 ft rectangular scrubber could handle a maximum of 8000 CFM entering air at 80°F, 20% relative humidity and 0.7 g particulates/m³ with a 1-sec residence time at a maximum pressure drop of 0.5 in. of water across the chamber. Water to the chamber’s 6 doublespray and 2 single-spray nozzle taps was supplied from recycle and makeup sources at pressures of 7.5–30 psig with total flows of 21.8–31.1 gpm depending on number of nozzle taps in use. These sprays effectively wetted the particulate- laden air and provided enough water to wash the collected particulate matter down the chamber walls. The four WR-10 nozzles used at the base of the scrubbing chamber provided fine conical spray patterns co-current with the air flow. The two sets of four F-20 nozzles used in the center portion of the chamber provided coarse flat sheet sprays perpendicular to the air flow path. Two large TR-50 nozzles at the top of the chamber provided the necessary coarse conical sprays to wash the collected particulates down the chamber wall to the trash-water separator below. Water flows through the nozzles were determined from pressure readings at each tap. Chamber pressure drop was determined by 15° inclined manometer readings taken across the chamber at the locations where the air inlet and outlet mean square velocities occurred.     

The Role of Pressure Drop and Flow Redistribution on Modeling Mercury Control Using Sorbent Injection in Baghouse Filters

Abstract

A mathematical model based on simple cake filtration theory was coupled to a reviously developed two-stage mathematical model for mercury (Hg) removal using powdered activated carbon injection upstream of a bag-house filter. Values of the average permeability of the filter cake and the filter resistance extracted from the model were 4.4× 10^?13 m² and 2.5 ×10^?4 m^?1, respectively. The flow is redistributed during partial cleaning of the filter, with flows higher across the newly cleaned filter section. The calculated average Hg removal efficiency from the baghouse is lower because of the high mass flux of Hg exiting the filter in the newly cleaned section. The model shows that calculated average Hg removal is affected by permeability, filter resistance, fraction of the baghouse cleaned, and cleaning interval.     

Effect of Bag Failure on Baghouse Outlet Loading

One of the most important considerations in baghouse operation is the effect of bag failure on outlet loading. This information would be Of use to equipment manufacturers, users, and regulatory officials. Unfortunately, little information is available in the literature on this aspect of baghouse performance. Equations describing changes in outlet loading resulting from the sudden rupture of one or more bags are developed from first principles. Calculated results from these equations are presented in the form of a chart which can very quickly and simply be used to obtain a numerical value for a revised outlet loading resulting from bag failure(s) for a variety of system conditions. Due to an assumption made in the derivation, the new outlet loading thus obtained represents the maximum increase (worst case conditions) to be expected from the rupture of one or more bags. The following variables are included in the analysis: inlet loading, outlet loading (prior to bag failure), number of bag failures, bag diameter, system pressure drop; and gas temperature.     

High-volume Impactor for Sampling Fine and Coarse Particles

Final design, calibration, and field testing have been completed for a new 1.13 m³/min (40 cfm) High-volume Virtual Impactor (HVVI). Field tests have demonstrated that the new classifier/collector works well as an accessory to the existing PM10 Size Selective Inlet high-volume samplers. The HVVI provides two fractions of PM10 mass, both of which are collected by filtration. The fine fraction (0-2.5 μm aero. dia.) Is collected on the standard 20.3 × 25.4 cm (8- × 10-in) high-volume filter; the coarse fraction (2.5-10 μm aero. dia.) is collected on a 5.1 × 15.2 cm (2- × 6-in) filter. Coarse flow through the receiver tubes is limited to 0.057 m³/min (2 cfm), 5 percent of the total flow.

The operating pressure drop across the HVVI stages Is sufficiently high to make changes In pressure across the collection filters Insignificant. The HVVI filter holder assembly facilitates loading/ unloading samples in the laboratory, thus eliminating damage due to handling filters in the field. Size separation characteristics of the HVVI agree well with those for the 16.7 L/min commercially available dichotomous sampler with the 50 percent effectiveness (cut-point) occurring at 2.5 μm. Applying laboratory-determined particle losses to the typical ambient particle mass size distribution described In Federal Register 49, 40 CFR, Part 53, Table D-3, the HVVI fine fraction total mass loss is less than 0.8 percent for liquid particles and less than 0.1 percent for solid particles; coarse fraction total mass loss is less than 2.5 percent for liquid particles, and less than 0.2 percent for solid particles.     

Performance of Fabric Filters on Cyclone Fired Boilers

This paper documents operation of reverse air fabric filters on Baltimore Gas and Electric’s C. P. Crane Units 1 and 2 cyclone boilers. Beginning immediately after startup, tubesheet pressure drop increased to high levels. Following stabilization with sonic horns and spare reverse air fans, an investigation was mounted. Diagnostic tools included both laboratory and slipstream pilot baghouses to determine cause and evaluate candidate methods of reducing pressure drop. Fundamental ash properties determined through laboratory pilot testing were in conformance with predictions. Alternate fabrics and coatings did not eliminate the problem. The root cause of the problem was that the amount of variable cake, i.e. that ash removed during cleaning, plays an important role in the dynamics of bag cleaning. These dynamics were absent in the C. P. Crane filters. Confirmation was obtained in the full scale baghouse through modification of the variable cake weight using ash reinfection. Finally, offsetting pressure drop and power consumption reductions have been obtained to achieve satisfactory operation of the baghouses.