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.     

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.     

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.     

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.     

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.     

Modeling of surface tension effects in venturi scrubbing

A modified model of venturi scrubber performance has been developed that addresses two effects of liquid surface tension: its effect on droplet size and its effect on particle penetration into the droplet. The predictions of the model indicate that, in general, collection efficiency increases with a decrease in liquid surface tension, but the range over which this increase is significant depends on the particle size and on the scrubber operating parameters. The predictions further indicate that the increases in collection efficiency are almost totally due to the effect of liquid surface tension on the mean droplet size, and that the collection efficiency is not significantly affected by the ability of the particle to penetrate the droplet.     

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 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.     

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.     

Joint US/USSR Test Program for Reducing Fly Ash Resistivity

An electrostatic precipitator preceded by a wet scrubber was tested at the Reftinskaya Power Station. The unit collects a high resistivity fly ash from the combustion of low sulfur Ekibastuz coal. The operating parameters of the precipitator were measured as well as the mass emissions and the in-situ electrical resistivity of the fly ash. Density, particle size distribution, electrical resistivity, and chemical composition were determined for collected samples of the fly ash. The fly ash was also characterized by x-ray diffraction and scanning electron microscopy. When a centrifugal wet wall scrubber was installed ahead of the electrostatic precipitator, the temperature of the flue gas entering the precipitator was decreased and the moisture content increased. The electrical resistivity of the fly ash was attenuated a decade, but not enough to overcome the adverse effects of back corona in the precipitator. Lowering the flue gas temperature to about 85°C by the addition of a venturi scrubber ahead of the centrifugal scrubber reduced the electrical resistivity of the fly ash another decade and allowed the operation of the precipitator without back corona.     

Performance of a Steam-Ejector Scrubber

The results of fractional and overall mass efficiency tests of a steam-ejector scrubber are presented. The tests were performed on one of seven modules of a full scale scrubber used for controlling particulate emissions from an open hearth furnace. Total flue gas particulate mass concentrations were determined at the inlet and outlet of the scrubber by conventional (Method 5) techniques. Inlet and outlet particulate concentrations as functions of diameter were determined on a mass basis using cascade impactors for sizes from about 0.3 μm to 5 μm, and on a number basis for diameters smaller than about 1 μm using optical and diffusional methods. Measurements were made under several scrubber operating conditions. The measured efficiencies based on total particulate mass concentrations with the scrubber operating under near optimum conditions ranged from 99.84 to 99.9%. The measured fractional efficiencies ranged from a maximum of 99.99% for particles having diameters of 1 μm to values of 97 and 99.9% for particles having diameters of 0.1, and 5 μm, respectively.     

Flux Force Condensation Aspirative Wet Scrubbing of Submicron Particles

A novel aspirative wet scrubber system makes use of condensation forces to enhance fine particulate collection. A pressure gain of 2 to 4 inches, W.C. is generated by the system and total water pump power requirements for multistage systems are 2 horsepower per thousand scfm. of gas throughput. No fans or blowers are utilized. When scrubbing hot combustion products carrying 0.1 to 6.0 micron metal oxide particles from a kiln, total collection efficiency was 99.4%. Collection of fly ash, in the particle size range 0.1 to 10 microns, has been measured at 99.5% efficiency.     

Characterization of Municipal Solid Waste Incineration Residues From Facilities with Different Air Pollution Control Systems

Abstract

Municipal Solid Waste incinerator residues produced in two types of facilities were exhaustively characterized: granulometry, mineralogy, chemical composition, leaching behavior, and elemental distribution as a function of particle size. Air Pollution Control (APC) residues coming from a semi-dry scrubber have shown higher solubility than fly ashes originating in an Electrostatic Precipitator (ESP), as well as higher contents in volatile metals (Cd, Hg). Different metal speciation and distribution as a function of particle size have been found in fly ashes (ESP residues) and APC residues. In APC residues, heavy metals (with the exception of Hg) show a parabolic distribution with maxima in the smallest and largest particles, following the same profile as soluble salts. Metal distribution for APC residues exhibits that metals generally are not associated with silicate aluminate matrix. Results show the effect of adding lime to APC residues in metal speciation and distribution.     

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.     

利用无泵水幕废气净化器治理高浓度NOx的工程实践

介绍了无泵水幕废气净化器的工作原理和运行特点,采用该设备处理某金刚石公司的酸洗车间高浓度的NOx气体,其净化效率达90%以上,净化后的NOx气体可直接达标排放.无泵水幕废气净化器解决了传统的水喷淋塔普遍存在的喷嘴堵塞、单级净化效率低、运行费用高等问题,在高浓度酸性气体治理方面具有很好的推广应用前景.     

Theoretical study of liquid droplet dispersion in a venturi scrubber

The droplet concentration distribution in an atomizing scrubber was calculated based on droplet eddy diffusion by a three-dimensional dispersion model. This model is also capable of predicting the liquid flowing on the wall. The theoretical distribution of droplet concentration agrees well with experimental data given by Viswanathan et al. for droplet concentration distribution in a venturi-type scrubber. The results obtained by the model show a non-uniform distribution of drops over the cross section of the scrubber, as noted by the experimental data. While the maximum of droplet concentration distribution may depend on many operating parameters of the scrubber, the results of this study show that the highest uniformity of drop distribution will be reached when penetration length is approximately equal to one-fourth of the depth of the scrubber. The results of this study can be applied to evaluate the removal efficiency of a venturi scrubber.     

Assessment and optimisation of VOC mass transfer enhancement by advanced oxidation process in a compact wet scrubber

Dimethyl disulphide (DMDS) removal was investigated in a compact scrubber (hydraulic residence time ≈20 ms), composed of a wire mesh packing structure where liquid and gas flow at co-current and high gas superficial velocity (>12 m s⁻¹). In order to regenerate the scrubbing liquid and to maintain a driving force in the scrubber, ozone and hydrogen peroxide were added to water since they allow the generation of nonselective and highly reactive species, hydroxyl radicals HO. Three ways of reagent distribution were tested. The influence of several parameters (liquid flow rate(s), ozone flow rate, pH and reagent concentrations) was investigated. The best configuration was obtained when ozone is transferred in the scrubbing liquid before introduction at the top of the scrubber simultaneously with the hydrogen peroxide solution, allowing to generate hydroxyl radical in the scrubber. With this configuration, DMDS removal could be increased from 16% with water to 34% at the same gas and liquid flow rates in the scrubber showing the potentiality of advanced oxidation process.     

Wet scrubber analysis of volatile organic compound removal in the rendering industry

The promulgation of odor control rules, increasing public concerns, and U.S. Environmental Protection Agency (EPA) air regulations in nonattainment zones necessitates the remediation of a wide range of volatile organic compounds (VOCs) generated by the rendering industry. Currently, wet scrubbers with oxidizing chemicals are used to treat VOCs; however, little information is available on scrubber efficiency for many of the VOCs generated within the rendering process. Portable gas chromatography/mass spectrometry (GC/MS) units were used to rapidly identify key VOCs on-site in process streams at two poultry byproduct rendering plants. On-site analysis was found to be important, given the significant reduction in peak areas if samples were held for 24 hr before analysis. Major compounds consistently identified in the emissions from the plant included dimethyl disulfide, methanethiol, octane, hexanal, 2-methylbutanal, and 3-methylbutanal. The two branched aldehydes, 2-methylbutanal and 3-methylbutanal, were by far the most consistent, appearing in every sample and typically the largest fraction of the VOC mixture. A chlorinated hydrocarbon, methanesulfonyl chloride, was identified in the outlet of a high-intensity wet scrubber, and several VOCs and chlorinated compounds were identified in the scrubbing solution, but not on a consistent basis. Total VOC concentrations in noncondensable gas streams ranged from 4 to 91 ppmv. At the two plants, the odor-causing compound methanethiol ranged from 25 to 33% and 9.6% of the total VOCs (v/v). In one plant, wet scrubber analysis using chlorine dioxide (ClO2) as the oxidizing agent indicated that close to 100% of the methanethiol was removed from the gas phase, but removal efficiencies ranged from 20 to 80% for the aldehydes and hydrocarbons and from 23 to 64% for total VOCs. In the second plant, conversion efficiencies were much lower in a packed-bed wet scrubber, with a measurable removal of only dimethyl sulfide (20-100%).     

Dioxin emissions after installation of a polishing wet scrubber in a hazardous waste incineration facility

Dioxin levels measured after wet scrubbing systems have been found to be higher than levels measured before the scrubber. It is believed that there is an adsorption of PCDD/Fs on plastic materials in the scrubber. The PCDD/F levels after a polishing wet scrubber were followed continuously for 18 months using long-time sampling equipment at a hazardous waste incineration facility in Sweden. Each sampling period lasted two weeks. It was found that the levels during and shortly after start-up periods were elevated. The decline was very slowly, which supports a memory effect in the scrubber. Further, a multivariate model showed that the relation between different homologues changed over time, which is in agreement with a desorption model, taking into account the vapour pressures for different congeners.     

Wet Scrubber Analysis of Volatile Organic Compound Removal in the Rendering Industry

Abstract

The promulgation of odor control rules, increasing public concerns, and U.S. Environmental Protection Agency (EPA) air regulations in nonattainment zones necessitates the remediation of a wide range of volatile organic compounds (VOCs) generated by the rendering industry. Currently, wet scrubbers with oxidizing chemicals are used to treat VOCs; however, little information is available on scrubber efficiency for many of the VOCs generated within the rendering process. Portable gas chromatography/mass spectrometry (GC/MS) units were used to rapidly identify key VOCs on-site in process streams at two poultry byproduct rendering plants. On-site analysis was found to be important, given the significant reduction in peak areas if samples were held for 24 hr before analysis. Major compounds consistently identified in the emissions from the plant included dimethyl disulfide, methanethiol, octane, hexanal, 2-methylbutanal, and 3-methylbutanal. The two branched aldehydes, 2-methylbutanal and 3-methylbutanal, were by far the most consistent, appearing in every sample and typically the largest fraction of the VOC mixture.

A chlorinated hydrocarbon, methanesulfonyl chloride, was identified in the outlet of a high-intensity wet scrubber, and several VOCs and chlorinated compounds were identified in the scrubbing solution, but not on a consistent basis. Total VOC concentrations in noncondensable gas streams ranged from 4 to 91 ppmv. At the two plants, the odor-causing compound methanethiol ranged from 25 to 33% and 9.6% of the total VOCs (v/v). In one plant, wet scrubber analysis using chlorine dioxide (ClO2) as the oxidizing agent indicated that close to 100% of the methanethiol was removed from the gas phase, but removal efficiencies ranged from 20 to 80% for the aldehydes and hydrocarbons and from 23 to 64% for total VOCs. In the second plant, conversion efficiencies were much lower in a packed-bed wet scrubber, with a measurable removal of only dimethyl sulfide (20–100%).