Operating History and Current Status of Fabric Filters in the Utility Industry

Electric utilities have made significant progress in recent years in designing and operating baghouses for collection of coal fly ash. As a result, early concerns with high operating and maintenance requirements and short bag lives are no longer an issue. With increasingly stringent air emissions regulations and imminent revision of the Clean Air Act, baghouses have become an attractive particulate collection option for utilities.

In order to keep its member utilities apprised of the latest design and operation and maintenance experience with baghouses, the Electric Power Research Institute has been conducting surveys of utility baghouse user experience. This paper presents results from the latest survey, conducted in 1989. A previous survey was conducted in 1985. The 1989 survey was conducted using questionnaires mailed to the utilities, telephone inquiries, and plant visits. This paper discusses the general trends observed in baghouse design, performance, operation and maintenance.     

1985 Update,Operating History and Current Status of Fabric Filters in the Utility Industry

Stringent particulate emissions limits and increasing awareness of stack opacity is leading the utility industry to use high efficiency particulate control systems. In response to this trend, the Electric Power Research Institute (EPRI) is conducting several research programs aimed at improving the operation, maintenance and performance of particulate control systems. One of these programs, RP-1401, “Reliability Assessment of Particulate Control Systems,” is developing operation, maintenance and design data bases for both electrostatic precipitators and fabric filters. This paper discusses some of the intermediate findings of the work done on fabric filters.     

Nodular Deposits in Fabric Filters

The retention of highly adherent fine particles in a fabric filter can cause a measurable difference in the forward and reverse air flow pressure drops. This difference, termed the check valve effect, results from the movement of aggregations or nodules of dust particles held by fibers on the surface or in the interstices of a fabric. The measurement of forward and reverse pressure drops is a useful method for determining the presence of nodules. Currently, we do not know of a simple way to prevent the formation of nodules nor to remove them easily once they form. However, we hope that in describing their effects, we may aid those individuals attempting to improve filter performance.     

Operation and Maintenance of Fabric Filters

Operation and maintenance and performing correct system monitoring of fabric filters is discussed. The anticipation of future problems at the time of start-up and the necessity of maintaining correct records on the system to assist in later troubleshooting is stressed. When all is going well, the fabric filter requires little but routine maintenance on moving parts, which is usually well identified in the service manuals. Problems usually appear as excessive emissions, high pressure drop, or inadequate bag life. In order to find the cause of these problems, one must have maintained sufficient Information on the system to identify what changed and when. With this information, there are logical paths to follow to the proper solutions.     

A Model for Pulse Jet Fabric Filters

ABSTRACT

A new model for pulse jet fabric filtration is proposed. In contrast to the earlier model of Ravin and Humphries,¹ which was formulated on the steady state assumption, the present study is aimed at developing a predictive capability for both transient and steady state operations, taking into account the compression effect of filter cakes. The model's relative simplicity allows frequent updating of the model parameter values, thus improving the accuracy of predictions. As a result, the model is particularly useful in developing control algorithms and designing controllers of pulse jet fabric filtration systems.     

Survey on the Use of Pulse-Jet Fabric Filters

Pulse-jet fabric filters rely on the filtration of dirty flue gas by the outside surface of the bags, which are then cleaned by a shock wave generated by an air pulse entering each bag from the top. As it travels down the length of the bag, the shock wave flexes the fabric and dislodges the dust cake. Enhancement of the pulse may be achieved by using a venturi, and cleaning may be on-line or off-line. This paper summarizes the results of an exhaustive study conducted for the Electric Power Research Institute to provide a convenient and versatile information base about the use of pulse-jet fabric filters on coal-fired boilers. Predominant features of the many pulse-jet installations identified by vendor survey and literature survey are shown in graphical and tabular form.     

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.     

Characterization of Sonic Devices Used for Cleaning Fabric Filters

ABSTRACT

Ozone reactivity scales play an important role in selecting which chemical compounds are used in products ranging from gasoline to pesticides to hairspray in California, across the United States and around the world. The California Statewide Air Pollution Research Center (SAPRC) box model that calculates ozone reactivity uses a representative urban atmosphere to predict how much additional ozone forms for each kilogram of compound emission. This representative urban atmosphere has remained constant since 1988, even though more than 25 years of emissions controls have greatly reduced ambient ozone concentrations across the United States during this time period. Here we explore the effects of updating the representative urban atmosphere used for ozone reactivity calculations from 1988 to 2010 conditions by updating the meteorology, emission rates, concentration of initial conditions, concentration of background species, and composition of volatile organic compound (VOC) profiles. Box model scenarios are explored for 39 cities across the United States to calculate the Maximum Incremental Reactivity (MIR) scale for 1,233 individual compounds and compound-mixtures. Median MIR values across the cities decreased by approximately 20.3% when model conditions were updated. The decrease is primarily due to changes in atmospheric composition ultimately attributable to emissions control programs between 1998 and 2010. Further effects were caused by changes in meteorological variables stemming from shifting seasons for peak ozone events (summer versus early fall). Lumped model species with the highest MIR values in 1988 experienced the greatest decrease in MIR values when conditions were updated to 2010. Despite the reduction in the absolute reactivity in the updated 2010 atmosphere, the relative ranking of the VOCs according to their reactivity did not change strongly compared to the original 1988 atmosphere. These findings indicate that past decisions about ozone control programs remain valid today, and the ozone reactivity scale continues to provide relevant guidance for future policy decisions even as new products are developed.

Implications: Updating the representative urban atmosphere used for the Maximum Incremental Reactivity (MIR) scale from 1988 to 2010 conditions caused the reactivity of 1223 individual compounds and combined mixtures to decrease by an average of 20.3% but the relative ranking of the VOCs was not strongly affected. This means that previous guidance about preferred chemical formulations to reduce ozone formation in cities across the United States remain valid today, and the MIR scale continues to provide relevant guidance for future policy decisions even as new products are developed.     

Some Recent Experience with Fabric Filters for Paniculate Collection

EPA's “Third Symposium on Fabric Filters for Particle Collection,” held in Tucson December 5 and 6, 1977, emphasized the results obtained from both laboratory and field experience. Data from selected new and/or continuing research programs as well as from new pilot and field applications are reviewed.     

Fabric Filter Technology for Utility Coal-Fired Power Plants

This is the fifth in a series of papers discussing the experience of electric utilities in applying baghouse technology for the collection of particulate matter at coal-fired electric power generating plants. The series presents new data obtained in research sponsored by the Electric Power Research Institute (EPRI) on reverse-gas and shake/deflate cleaned baghouses, and specifically addresses a number of unresolved issues in the design and operation of these units. This paper describes research to improve reverse-gas cleaning technology, and to characterize reverse-gas sonic assisted and shake/deflate cleaning.     

Preliminary Estimates of Performance and Cost of Mercury Control Technology Applications on Electric Utility Boilers

ABSTRACT

Under the Clean Air Act Amendments of 1990, the U.S. Environmental Protection Agency (EPA) determined that regulation of mercury emissions from coal-fired power plants is appropriate and necessary. To aid in this determination, preliminary estimates of the performance and cost of powdered activated carbon (PAC) injection-based mercury control technologies were developed. This paper presents these estimates and develops projections of costs for future applications.

Cost estimates were developed using PAC to achieve a minimum of 80% mercury removal at plants using electrostatic precipitators and a minimum of 90% removal at plants using fabric filters. These estimates ranged from 0.305 to 3.783 mills/kWh. However, the higher costs were associated with a minority of plants using hot-side electrostatic precipitators (HESPs). If these costs are excluded, the estimates range from 0.305 to 1.915 mills/kWh. Cost projections developed using a composite lime-PAC sorbent for mercury removal ranged from 0.183 to 2.270 mills/kWh, with the higher costs being associated with a minority of plants that used HESPs.     

Fabric Filter Technology for Utility Coal-Fired Power Plants

This is the sixth and last part in a series of papers discussing the experience of electric utilities in applying baghouse technology for the collection of particulate matter at coal-fired electric power generating plants. The series presents new data obtained in research sponsored by the Electric Power Research Institute (EPRI) on reverse-gas and shake/deflate cleaned baghouses, and specifically addresses a number of unresolved issues in the design and operation of these units. This paper discusses research, development and demonstration activities now underway or planned to further understand baghouse technology to ensure efficient, economic and reliable service in utility applications. In addition, it summarizes the major findings reported in Parts I through V.     

Fabric Filter Technology for Utility Coal-Fired Power Plants

This is the third in a series of papers discussing the experience of electric utilities in applying baghouse technology for the collection of particulate matter at coal-fired electric power generating plants. The series presents new data obtained in research sponsored by the Electric Power Research Institute (EPRI) on reverse-gas and shake/deflate cleaned baghouses, and specifically addresses a number of unresolved issues in the design and operation of these units. This paper provides an overview of the design and operating characteristics of baghouses now in place in the utility industry. In addition, it discusses three key issues in design and operation: the relationships among dust cake weight and chemical composition, air-to-cloth ratio, and pressure drop; fabric selection; and bag life.     

Fiber Glass Fabric Filters for High Temperature Dust and Fume Control

Foliar markings on vegetation have proven a highly sensitive criterion for the presence of many air pollutants; proper evaluation of such effects can serve as a valuable and inexpensive tool for delineating an air pollution condition. Injury symptoms from fluoridt, sulfur dioxide, photochemical oxidants and other pollutants have been described and can be recognized by experienced observers. Field studies provide a valuable technique for appraising an air pollution problem when diagnosis is not confused by other factors. Careful inspection can avert difficulties arising in diagnosis where similar symptoms are produced by agents other than air pollutants. Several factors must be considered in appraising injury. These include a knowledge of the relative sensitivity of plant species to various pollutants, the syndrome of injury on a number of plants and species, and distribution and geographic relation of affected plants to the suspected source. Background information on cultural, environmental, disease and insect conditions which might be responsible for, or modify, foliar markings or chronic effects in question must also be understood. For some pollutants a chemical analysis of foliage and air may prove helpful. When these factors are studied, the presence, distribution and magnitude of an air pollution situation can be evaluated, thus providing a sensitive criterion of air quality.     

Economic Comparison of Selected Scenarios for Electrostatic Precipitators and Fabric Filters

Compliance with particulate standards for utility boilers burning low sulfur western coal has resulted in the installation and proposed installation of several fabric filter collectors where cold or hot electrostatic precipitators would have traditionally been applied. Recently, SO3 conditioning has been used to improve cold precipitator performance resulting in considerable reduction in specific collection area (SCA). All this suggests that trade-offs exist indicating ranges of SCA, A/C ratio, and power plant size (Mw) where fabric filters become competitive with electrostatic precipitators. Conceptual cost models are presented which indicate total capital investment and annual costs for the control devices. Precipitator costs are correlated with collecting area, gas flow rate, and power input and are presented as functions of SCA and Mw. Fabric filter costs are keyed to gross filter area, pressure drop, and gas flow rate. Fabric filters become competitive when a cold precipitator requires SCAs in excess of 600 to 800 and competitive when a hot precipitator requires equivalent cold precipitator SCAs in excess of 600 to 1000 depending on A/C ratio, Mw, and hot precipitator SCA credit allowance. The S0₃ conditioned precipitator scenario is shown to be economically competitive with fabric filters.     

Performance and Cost Comparisons between Fabric Filters and Alternate Participate Control Techniques

A study was conducted to evaluate performance and cost comparisons of fabric filters and alternate fine particulate control techniques. In relating the removal of fine particulate to costs, due to the lack of fractional efficiency data, it was found necessary to treat a specific application in order to make the study manageable. The case chosen is that of the coal fired industrial boiler since Enviro-Systems has a pilot program in this application area.     

Fabric Filter Applications on Coke Oven Pushing Operations

Coke oven pushing emissions containing quantities of tars and dust require new approaches to adapt fabric filter collectors. This paper deals with the Wheelabrator/Taisei precoat filter systems being used on coke oven pushing operations. The Taisei test program and the filter installation at Tokyo Gas are discussed. The variables to be evaluated in the design of a fabric filter emission control system are examined.     

Effect of Dust Size Distribution on the Collection Efficiency of Pulse-Jet Fabric Filters

Recent advances in vehicle emission control technology have reduced the effectiveness of the conventional tailpipe test used In inspection and maintenance programs. A different approach Is being followed in Harris County, Texas (Houston area), based on identification and correction of misfuellng and tampering. Misfueling Is being identified by using a lead-sensitive test paper to detect lead deposits in the tailpipe that result from using leaded gasoline. Field tests of this procedure demonstrated that it Is reliable and accurate for the Intended purpose. The data also indicated the need to observe certain precautions to avoid contamination and other potential sources of error. This procedure and other emission-related checks have been added to the annual safety inspections. These tests are conducted on vehicles of 1980 model year and later, by approximately 1150 Inspection stations throughout the county that conduct annual safety Inspections. Experience with the first few months of this program has been excellent.