Emission Control in Coking Operations By Use of Stage Charging

At the Clairton Coke Works of the United States Steel Corporation (the world’s largest coke plant), with coal charges of about 30,000 net tons per day, a system designated as “stage charging” has been developed for charging coal into the coke oven chamber without emissions to the atmosphere. The principles of the system are based on controlled sequential flow of the coal from the charging hoppers, during which the oven chamber is maintained under a very slight negative pressure condition by use of steam aspiration in the offtakes for on-the-main charging. The techniques are basic but require knowledge of the coal characteristics, adequate and properly maintained aspirating systems, including clean offtake piping, control of coal volume in the individual hoppers, and last, and probably most important, adherence by the operating crew to specific charging and leveling practices.     

Charged Fog Technology Part II: Prototype Tests of a New Charged Fog Generator for Fugitive Emission Control

The prototype charged fog generator described in a preceding paper¹ was field tested on a fugitive emission source at a bentonite ore processing plant in Worland, Wyoming, during 1981. Participate matter samples were collected as fine and coarse fractions under three different test scenarios: with no control, with partial control (uncharged fog), and with full control (charged fog). Measured particulate matter sample concentrations were normalized for each test day with respect to the background values so that particle control efficiency of the device could be evaluated without any bias during the entire test program.

These tests have shown that mean value of the inhalable particle control efficiency of charged fog measured under all instrument settings and field conditions is increased by 78% when compared with uncharged fog. In particular, fine particle control efficiencies of over 90% were recorded under optimum instrument settings and ideal field conditions. The bentonite particles seemed to carry a net positive charge. The optimum instrument settings were found to be: 60 L/h water flow rate, an applied voltage of 10-15 kV and a spray pattern which covers maximum volume of dust-laden air. Ideal field conditions are high relative humidity and calm or low winds.

Charged fog technology appears to be an effective and economically feasible method to control sources of fugitive particle emission in the inhalable size range. Further research is needed to evaluate the inhalable particle control efficiency of the device for emissions of various chemical compositions.     

Fugitive Dust Emission Source Profiles and Assessment of Selected Control Strategies for Particulate Matter at Gravel Processing Sites in Taiwan

Abstract

Particles emitted from gravel processing sites are one contributor to worsening air quality in Taiwan. Major pollution sources at gravel processing sites include gravel and sand piles, unpaved roads, material crushers, and bare ground. This study analyzed fugitive dust emission characteristics at each pollution source using several types of particle samplers, including total suspended particulates (TSP), suspended particulate (PM₁₀), fine suspended particulate (PM_2.5), particulate sizer, and dust-fall collectors. Furthermore, silt content and moisture in the gravel were measured to develop particulate emission factors. The results showed that TSP (<100 µm) concentrations at the boundary of gravel sites ranged from 280 to 1290 µg/m³, which clearly exceeds the Taiwan hourly air quality standard of 500 µg/m³. Moreover, PM₁₀ concentrations, ranging from 135 to 550 µg/m³, were also above the daily air quality standard of 125 µg/m³ and approximately 1.2 and 1.5 times the PM_2.5 concentrations, ranging from 105 to 470 µg/m³. The size distribution analysis reveals that mass mean diameter and geometric standard deviation ranged from 3.2 to 5.7 µm and from 2.82 to 5.51, respectively. In this study, spraying surfactant was the most effective control strategy to abate windblown dust from unpaved roads, having a control efficiency of approximately 93%, which is significantly higher than using paved road strategies with a control efficiency of approximately 45%. For paved roads, wet suppression provided the best dust control efficiencies ranging from 50 to 83%. Re-vegetation of disturbed ground had dust control efficiencies ranging from 48 to 64%.     

Lime/Limestone Scrubber Operation and Control

This paper examines operating and control experience obtained at full-scale lime-limestone scrubber systems both in the eastern and western United States. Methods of resolving typical problems in pH control of reagent feed, water balance closure, and slurry solids de-watering are discussed and described. Control problems can be severely aggravated by scale formation inside scrubbing equipment, especially on control sensors. If the sensor reliability problems can be resolved in a properly-designed scrubbing system, then the scrubber chemistry can generally be controlled and scale formation can usually be prevented. Current regulatory trends towards zero blowdown requirements increase scrubber operating and control problems, both from a process control standpoint (due to system complexity) and from a sensor reliability standpoint (due to an increased likelihood for chemical scale formation). These factors highlight the need for continuing development of improved scrubbing systems.     

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.     

Evaluation of VOC Emission Measurement Methods for Paint Spray Booths

Abstract

Interest in regulations to control solvent emissions from automotive painting systems is increasing, especially in ozone nonattainment areas. Therefore, an accurate measurement method for VOC emissions from paint spray booths used in the automotive industry is needed to ascertain the efficiency of the spray booth capture and the total emissions. This paper presents the results of a laboratory study evaluating potential VOC sampling and analytical methods used in estimating paint spray booth emissions, and discusses these results relative to other published data. Eight test methods were selected for evaluation. The accuracy of each sampling and analytical method was determined using test atmospheres of known concentration and composition that closely matched the actual exhaust air from paint spray booths. The solvent mixture to generate the test atmospheres contained a large proportion of polar, oxygenated hydrocarbons such as ketones and alcohols. A series of identical tests was performed for each sampling/analytical method with each test atmosphere to assess the precision of the methods. The study identified significant differences among the test methods in terms of accuracy, precision, cost, and complexity.     

Localizing Gaseous Fugitive Emission Sources by Combining Real-Time Optical Remote Sensing and Wind Data

ABSTRACT

This paper presents a new approach to localize point emissions from ground-level fugitive gaseous air pollution sources. We estimate the crosswind plume's ground-level peak location downwind from the source by combining smooth basis functions minimization (SBFM) with path-integrated optical remote sensing concentration data acquired along the crosswind direction in alternating beam path lengths. Peak location estimates, in conjunction with real-time measured wind direction data, are used to reconstruct the fugitive source location. We conducted a synthetic data study to evaluate the proposed peak location SBFM reconstruction. Furthermore, the methodology was validated with open-path Fourier transform infrared concentration data collected with wind direction data downwind from a controlled point source. This approach was found to provide reasonable estimates of point source location. The field study reconstructed source location was within several meters of the real source location.     

Charged Droplet Scrubbing for Fine Particle Control

Some basic mechanisms of interaction of highly charged scrubbing droplets with fine particulate are studied. In the fine particulate size range (1.0-0.1 micron), the most effective mechanisms are electrically augmented impact scrubbing and charge exchange without impact. A charged droplet scrubber using electrohydrodynamically sprayed droplets and an applied field to achieve electrical impact scrubbing is described. It is shown that such scrubbers are capable of high densities of droplets in the 100 jum size range, and charged to near their upper stability limit. Collection efficiencies of 30 to 50% per stage are demonstrated in the submicron particulate size range.     

Ambient Air Quality and Automotive Emission Control

This paper is concerned with uncertainties involved in projecting ambient air quality. Ambient air quality was projected by assuming a linear dependence on estimated future emissions. Future automotive emissions were estimated by a method recommended by EPA. Projections were made for the locations reported to have the highest ambient air concentrations of each pollutant; Chicago for carbon monoxide and the California South Coast Air Basin for hydrocarbon and oxidant. The sensitivity of the projections to several input parameters was determined.

The uncertainty in projection of air quality due to the use of a maximum, once-per-year concentration is large. For example, the reduction in total CO emissions in Chicago in 1975, necessary to meet the air quality standard, was as high as 68% or as low as 26%, depending on whether the historic high, 8 hr average concentration of 44 ppm or the 1970 maximum of 21 ppm was used. The effects of uncertainties in growth rates and fraction of emissions attributed to the automobile were also sizeable. Differences in automotive growth rate had a large near-term effect on projected concentrations, while differences in nonautomotive growth rate or fraction of emissions attributed to the automobile had a large long-term effect. The effect of 1975 interim automotive emission standards on projected air quality was negligible when compared with projected air quality based on the previous Federal automotive emission standards for 1975.     

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.     

Nitrogen Oxides Emission Control Options for Coal-Fired Electric Utility Boilers

Abstract

Recent regulations have required reductions in emissions of nitrogen oxides (NO_x) from electric utility boilers. To comply with these regulatory requirements, it is increasingly important to implement state-of-the-art NO_x control technologies on coal-fired utility boilers. This paper reviews NO_x control options for these boilers. It discusses the established commercial primary and secondary control technologies and examines what is being done to use them more effectively. Furthermore, the paper discusses recent developments in NO_x controls. The popular primary control technologies in use in the United States are low-NO_x burners and overfire air. Data reflect that average NO_x reductions for specific primary controls have ranged from 35% to 63% from 1995 emissions levels. The secondary NO_x control technologies applied on U.S. coal-fired utility boilers include reburning, selective noncatalytic reduction (SNCR), and selective catalytic reduction (SCR). Thirty-six U.S. coal-fired utility boilers have installed SNCR, and reported NO_x reductions achieved at these applications ranged from 15% to 66%. Recently, SCR has been installed at >150 U.S. coal-fired utility boilers. Data on the performance of 20 SCR systems operating in the United States with low-NO_x emissions reflect that in 2003, these units achieved NO_x emission rates between 0.04 and 0.07 lb/10⁶ Btu.     

Nomogram for Relating Particle and Particle Cloud Parameters

Three concentration units, i.e., mass density, number density, and surface area, often are alternatively used to describe an aerosol cloud. While most aerosol clouds are composed of poly-disperse particles, the nomogram based upon monodisperse spherical particles (Figure 1) has been found useful for relating these different concentration values.     

Innovative Approach for Estimating Fugitive Gaseous Fluxes Using Computed Tomography and Remote Optical Sensing Techniques

ABSTRACT

This paper presents a new approach to quantify emissions from fugitive gaseous air pollution sources. The authors combine Computed Tomography (CT) with Path-Integrated Optical Remote Sensing (PI-ORS) concentration data in a new field beam geometry. Path-integrated concentrations are sampled in a vertical plane downwind from the source along several radial beam paths. An innovative CT technique, which applies the Smooth Basis Function Minimization method to the beam data in conjunction with measured wind data, is used to estimate the total flux from the fugitive source. The authors conducted a synthetic data study to evaluate the proposed methodology under different meteorological conditions, beam geometry configurations, and simulated measurement errors. The measurement errors were simulated based on data collected with an Open-Path Fourier Transform Infra-Red system. This approach was found to be robust for the simulated errors and for a wide range of fluctuating wind directions. In the very sparse beam geometry examined (eight beam paths), successful emission rates were retrieved over a 70° range of wind directions under extremely large measurement error conditions.     

Economic Comparison of Emission Control Systems for Glass Manufacturing Furnaces with Heat Recovery

ABSTRACT

Glass manufacturing, like other process industries, is faced with air pollution compliance problems due to ever stricter emission limits. Several waste gas cleaning equipment options are available for air pollution control (APC) in glass plants, the most common arrangements being based on electrostatic precipitator (ESP) or fabric filter (FF) dust collectors and semi-wet or dry processes for acid gas removal. However, several counteracting aspects affect the choice of gas cleaning technologies, which are confirmed by the discrepancies encountered in actual suppliers' bids. In this paper, the main pollution control options are analyzed by carrying out a critical comparison under the cost-effectiveness point of view to select the lowest cost arrangement considering capital investment, operating expenses, and energy-saving revenues from heat recovery processes. The analysis is carried out with reference to a case study involving actual float glass production lines at Pilkington plants in Italy.     

Superior Pillared Clay Catalysts for Selective Catalytic Reduction of Nitrogen Oxides for Power Plant Emission Control

ABSTRACT

Fe³+-, Cr³+-, Cu²+-, Mn²+-, Co²+-, and Ni²+-exchanged Al₂O₃-pillared interlayer clay (PILC) or TiO₂-PILC catalysts are investigated for the selective catalytic reduction (SCR) of nitric oxide by ammonia in the presence of excess oxygen. Fe³+-exchanged pillared clay is found to be the most active. The catalytic activity of Fe-TiO₂-PILC could be further improved by the addition of a small amount of cerium ions or cerium oxide. H₂O and SO₂ increase both the activity and the product selectivity to N₂. The maximum activity on the Ce-Fe-TiO₂-PILC is more than 3 times as active as that on a vanadium catalyst. Moreover, compared to the V₂O₅-WO₃/TiO₂ catalyst, the Fe-TiO₂-PILC catalysts show higher N₂/N₂O product selectivities and substantially lower activities (by ~85%) for SO₂ oxidation to SO₃ under the same reaction conditions. A 100-hr run in the presence of H₂O and SO₂ for the CeO₂/Fe-TiO₂-PILC catalyst showed no decrease in activity.     

Emission Standards for the Control of Solid Particles,A New Approach by New Jersey

Existing chapters of the New Jersey Air Pollution Control Code are described, followed by an explanation of a proposed new chapter to control emissions of coarse solid particles and fine solid particles from industrial processes. The chapter is designed to limit dustfall of coarse particles off the premises of the emitter to WO tons per square mile per year, and the methods used to relate this criterion to stack emissions are explained. Fine particles, suspended in the air off the premises, are limited to 0.615 milligrams per cubic meter during average weather conditions. Measures taken for the protection of buildings, where the plant property line is less than 10 stack heights from the base of the stack, are described.     

The Use of Nahcolite Ore and Bag Filters For Sulfur Dioxide Emission Control

This paper describes some technical and economic aspects of the nahcolite ore injection process for the simultaneous removal of fly ash and sulfur oxides from stack gases. The process is capable of removing greater than 99% of the particulate matter and greater than 70% of the sulfur oxides present in such gases. In the process, nahcolite ore, a naturally occurring material containing 70 to 90% sodium bicarbonate, is ground to 90% passing through —200 mesh screens. Approximately 20% of the ground ore is used to precoat the filter bags in a baghouse filter while the remainder of the material is fed into the flue gas Just ahead of the baghouse. The flue gas is drawn through the baghouse by induced draft fans and sent up the stack. Most of the SO₂ and practically all of the fly ash in the flue gas can be removed as the gas passes through the filter bags. The spent nahcolite ore and fly ash are collected and conveyed to waste disposal as landfill, or alternatively processed for insolubilization by coprecipitation prior to landfilling. The technical feasibility of the process has been demonstrated in both bench scale and pilot scale engineering studies. Economic analyses performed for the cases of plants located in the midwest and southwest indicate lower capital costs for the nahcolite injection process when compared to wet scrubbing. On an annual cost basis, the nahcolite ore Injection process is comparable in cost to wet scrubbing for the case of the southwestern power plant, and somewhat more expensive for the case of the midwestern plant.