Problems of Meeting Multiple Air Quality Objectives for Coal-Fired Utility Boilers

Gaseous wastes and particulate emissions are produced in the process of burning coal to produce electrical energy. In attempting to control these gaseous wastes, changes in the operation efficiency of boilers and secondary equipment are likely to result, and in addition liquid and solid waste streams are produced. The interrelationships among the various forms of wastes and the effects of air quality control on process efficiency are often overlooked in studies of environmental quality management.

The study was undertaken to evaluate the technical alternatives for handling gaseous and particulate emissions from coal-fired boilers and to determine the feasibility of meeting several standards simultaneously. The gaseous emissions of major importance in the combustion of coal are parti culates, oxides of sulfur, and oxides of nitrogen. Particulates can be controlled by a tradeoff among further preparation at the mine (for additional ash removal), type of boiler, use of dust control equipment and high stacks for dispersion of residual emissions, if ambient air standards are considered. Oxides of sulfur reduction depends currently on fuel substitution, limestone additives in the boiler and some form of contact process such as wet scrubbing, or the use of high stacks. Oxides of nitrogen control in coal fired boilers is restricted to small reductions by either changes in boiler operation, such as lower excess air levels, adsorption during wet scrubbing or by dispersion from high stacks.     

Application of Dry Flue Gas Scrubbing to Hazardous Waste Incineration

Dry scrubbing of the flue gas from chemical waste incineration is becoming an increasingly viable alternative to wet scrubbing. This paper discusses the relative advantages and disadvantages of wet and dry scrubbing systems and compares the relative capital and operating costs. The design parameters of the dry scrubbing process are discussed, including reagent atomization, gas dispersion, gas temperatures, and particulate removal. The history of dry scrubbing process applications is discussed, including the successful European hazardous waste systems. Finally, a comparison is made among three very different hazardous waste incinerators in the U.S. that will utilize dry scrubbing systems.     

The Feasibility of Wet Scrubbing for Treating Waste-to-Energy Flue Gas

The selection of Hue gas treatment processes in the waste-to-energy industry has generally followed the trend of the coal-fired power industry. The highly favored process for both industries is the dry scrubber (spray absorber) followed by a fabric filter. As more attention is focused upon increasingly greater efficiencies, lower outlet concentrations, heavy metals emissions, and toxic organic pollutant emissions, the advantages of wet scrubbing become more pronounced. This paper provides an objective technical and economic evaluation of selected wet scrubbing and dry scrubbing systems for a generic waste-to-energy facility. The advantages and disadvantages of wet scrubbing are discussed and translated into cost benefits or penalties.     

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.     

Pollution Control Progress

A scrubbing process for flue gas desulfurization, based upon naturally occurring carbonate rocks, has been developed from laboratory to pilot plant scale. Calcitic limestones are better sulfur dioxide absorbents than dolomitic ones when used in the slurry form. The process was tested on a 200-cfm pilot plant on a coal-fired boiler. Various types of scrubbing equipment were evaluated. Up to 80 per cent sulfur dioxide removal was feasible. The consumption of limestone ranged between 20 and 30 per cent more than the stoichiometric requirements.     

FF/C Scrubber Demonstration on a Secondary Metals Recovery Furnace

A flux force/condensation (FF/C) scrubbing system was built to control participate emissions from a secondary metals recovery furnace. Total mass penetration and fractional penetration measurements were made under several different operating modes. The performance of the demonstration scrubber was consistent with the results of previous studies on FF/C scrubbing. The system was generally capable of 90 to 95 % efficiency on particles with a mass median aerodynamic diameter of 0.75 µA. This efficiency was achieved with a 68 cm (27 in.) W.C. gas-phase pressure drop.     

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.     

Asbestos: Rationale Behind A Proposed Air Quality Standard

A computerized simulation model has been developed to compute energy requirements of a limestone slurry flue gas desulfurization (FGD) system as a function of FGD system design parameters, power plant characteristics, coal properties, and sulfur dioxide emission regulation. Results are illustrated for a "base case" plant of 500 MW, burning 3.5% sulfur coal, meeting the federal new source performance standard of 1.2 lb SO₂/10⁶ Btu. The flue gas is cleaned by an electrostatic precipitator followed by a limestone FGD system with a TCA scrubbing vessel and an optimized in-line steam reheater. The total FGD system energy requirement for this case was found to be 3.4% of the total energy input to the boiler. Sensitivity analyses were then performed in which the nominal values of ten system parameters were individually varied. This caused the total FGD system energy requirement to vary between 2.5 % and 6.1 % of the gross plant output for the range of parameters tested. The most sensitive parameters were found to be scrubbing slurry pH, which affects pumping requirements, and stack gas exit temperature, which affects reheat requirements. In all cases, FGD energy requirements were minimized when the SO₂ emission standard was met by partially bypassing the scrubber. In light of the recent Clean Air Act Amendments this option may not be feasible in the future.     

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.     

Field enhancements of packed-bed performance for low-concentration acidic and basic-waste gases from semiconductor manufacturing process

Low-concentration acidic and basic-waste gas pollutants contribute significantly in the total emission of a facility. Previous results show that the control of high volumetric flow rate (approximately 500 m3/min), low-concentration acidic (< 1 ppm by vol) and basic (< 3 ppm by vol) gases from semiconductor process vent, by conventional wet scrubbing technique is a challenging task. This work was targeted to enhance the performance of packed beds for high-volumetric flow rate, low-concentration acidic (HF, HCl), and basic (NH3)-waste gases from the semiconductor manufacturing process. The methodology used to meet the goal was the application of fine-water mist over the inlet stream before entering to the packed bed and use of the surfactant with mist/packed-bed liquid in low concentration. An experimental study was carried out in two acid-packed beds to optimize the operating conditions, such as pH of the liquid, circulating liquid flow rate, blow-down cycle, and so forth. The relationship among liquid pH, liquid ionic concentration, and the removal efficiency of the packed bed for the pollutants has been discussed considering chemical equilibrium, two-film theory, and Henry's law. For the potential utilization of scrubbing water, the dependency of the efficiency on blow-down cycle was studied, and a mechanism is suggested. The proposed water-mist surfactant system was installed in two acid-packed beds, and performance of the packed beds was compared. The background efficiencies of the acid-packed beds for HF, HCl, and NH3 were found max to be (n = 11) 53, 40, and 27%, whereas after installation of the system, they increased significantly and became 76 +/- 13% (n = 10), 76 +/- 8% (n = 7), and 78 +/- 7% (n = 7), respectively, for inlet concentrations of HF and HCl < 1 ppm and NH3 < 14 ppm. The mechanism by which the surfactants operate to enhance the removal in scrubbing process is suggested considering the hydrodynamic effect and the interfacial effect with the charge-generating characteristic of surfactants on water surface, when dissolved into water. The results show that a proposed rectification system can effectively reduce the emission rates below the regulatory level (0.6 kg/hr) at the present conditions of the facility.     

钢棒去皮机除尘器设计

钢棒去皮机是通过砂轮磨削除去钢棒表面铁锈的一种设备，在去皮过程产生的大量金属粉尘，导致环境污染，为此设计喷淋塔式除尘器作为钢棒去皮机的除尘装置。通过选择和计算的运行参数，设计了喷淋塔的结构和尺寸。对设计的除尘器效率验算结果表明：该除尘器可以满足去皮机环保要求，除尘效率达99．7％。     

钢棒去皮机除尘器设计

钢棒去皮机是通过砂轮磨削除去钢棒表面铁锈的一种设备,在去皮过程产生的大量金属粉尘,导致环境污染,为此设计喷淋塔式除尘器作为钢棒去皮机的除尘装置。通过选择和计算的运行参数,设计了喷淋塔的结构和尺寸。对设计的除尘器效率验算结果表明:该除尘器可以满足去皮机环保要求,除尘效率达99.7%。     

旋流塔板叶片仰角对湿钙法烟气脱硫过程的影响

实验研究了旋流塔板叶片仰角对钙基湿法烟气脱硫工艺的影响。结果表明 ,一般情况下 ,叶片仰角增大 ,脱硫率有所下降 ,塔的运行稳定性有所下降 ,结垢有所增加。因此 ,在将麻石水膜除尘器改造成旋流板塔脱硫除尘系统的过程中 ,增大叶片仰角的同时一定要考虑脱硫率的下降问题。     

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.     

Submicron Particulate Scrubbing with a Two Phase Jet Scrubber

The two phase jet scrubbing system utilizes waste thermal energy to provide the operating power for a two phase jet which simultaneously cleans and induces the necessary draft. Tests results have shown excellent cleaning performance and a substantially reduced operating cost.     

Atomization and Cloud Behavior In Venturi Scrubbing

The exact collection mechanism of a venturi scrubber has been unknown up to this time. Photographic stop-action techniques and glass venturi scrubbers have made it possible to establish where and how particles are captured and to speculate on possible gas removal possibilities. This report extends the knowledge of pneumatic atomization which is used in gas scrubbing and many other applications by providing further information on cloud-type atomization. Cloud-type atomization which is produced by pneumatic atomization of liquid streams (not drops) results in the formation of liquid droplets which appear to be less than 10 microns in diameter. These droplets coalesce and form clouds which move as single entities. Effective overall cloud diameters are determined to be a function of the velocity of the atomizing gas stream. The effective cloud diameters start at 170 [a and increase as throat gas velocities increase from 150 ft/sec. Throat velocities and liquid inlet nozzle diameters necessary to obtain water clouds of specific effective diameters can be estimated.

These large clouds are efficient impaction targets and stop most of the particulate matter within 0.5 cm from the throat scrubbing liquid inlets. High gas absorption is expected for the clouds of droplets because turbulent gas movement can exist inside and outside the clouds and the 10 μ droplets provide exceptional surface area.     

Memory effect on the dioxin emissions from municipal waste incinerator in Taiwan

Evaluation of the dioxin removal efficiency of the air pollution control device (APCD) at an existing municipal waste incinerator (MWI) located in Taiwan is conducted via stack sampling and analysis. The MWI investigated is equipped with cyclones, dry lime scrubbing systems and fabric filters as APCDs. Results indicate that the patterns of dioxin isomers at APCDs' inlet and stack are similar. During the first year of carbon injection, the concentrations of emitted dioxin decreased greatly. The dioxin removal efficiency increased from 26.9% to 96.6% after injecting 115 kg/day activated carbon (AC). At the second year, the dioxin removal efficiency reaches 98.7% after injecting the same rate of AC continuously. The lower efficiency achieved with activated carbon injection (ACI) during the first year can be attributed to the memory effect, i.e. the dioxin or precursor desorbs slowly to the flue gas and increases the dioxin concentration at stack, resulting in a lower dioxin removal efficiency than expected.     

Comparison between absorption and biological activity on the efficiency of the biotrickling filtration of gaseous streams containing ammonia

Polluted air streams can be purified using biological treatments such as biotrickling filtration, which is one of the most widely accepted techniques successfully tuned to treat a wide variety of exhausted gaseous streams coming from a series of industrial sectors such as food processing, flavor manufacturers, rendering, and composting. Since the degradation of a pollutant occurs at standard pressure and temperature, biotrickling filtration, whether compared with other more energy-demanding chemical-physical processes of abatement (such as scrubbing, catalytic oxidation, regenerative adsorption, incineration, advanced oxidation processes, etc.), represents a very high energy-efficient technology. Moreover, as an additional advantage, biodegradation offers the possibility of a complete mineralization of the polluting agents. In this work, biotrickling filtration has been considered in order to explore its efficiency with respect to the abatement of ammonia (which is a highly water-soluble compound). Moreover, a complete mathematical model has been developed in order to describe the dynamics of both absorption and biological activities which are the two dominant phenomena occurring into these systems. The results obtained in this work have shown that the absorption phenomenon is very important in order to define the global removal efficiency of ammonia from the gaseous stream (particularly, 44% of the ammonia is abated by water absorption). Moreover, it has been demonstrated (through the comparison between experimental results and theoretical simulations) that the action of bacteria, which enhance the rate of ammonia transfer to the liquid phase, can be modeled through a simple Michaelis-Menten relationship.

     

Alternative Strategies for Control of Sulfur Dioxide Emissions

Achievement of air quality goals now more than ever requires careful consideration of alternative control strategies in view of national concerns with energy and the economy. Three strategies which might be used by coal-fired steam electric plants to achieve ambient air quality standards for sulfur dioxide have been compared, and the analysis shows that the desired objective can be achieved using the intermittent control strategy with substantially less impact on the environment, less consumption of energy, and at a much lower economic cost than using either stack gas scrubbing or low-sulfur coal.     

A Study of Primary Sulfate Emissions From a Coal-Fired Boiler with FGD

A study was carried out to investigate the emissions of SO₂ and primary sulfate materials (H₂SO₄ and inorganic particulate matter) from a boiler burning fossil fuel and using a wet-limestone scrubber for SO₂ removal. Experiments were designed to assess the scrubbing efficiency for SO₂ and sulfate, as well as the potential for scrubber liquor reentrainment. The boiler studied was an 820 MW cyclone-fired unit equipped with a wet, limestone scrubber, consisting of eight two-stage venturi-absorber modules designed to treat a flue gas flow rate of 2,760,000 acfm. The boiler fuel was a low-grade sub-bituminous coal with ash and sulfur contents of 25 and 5%, respectively. Multiple-sampling methods were employed concurrently on the inlet and outlet of a candidate absorber module to measure SO₂, total water-soluble sulfate, and free H₂SO₄. Samples were collected during three field experiments from September 1977 through April 1978. The average SO₂ scrubbing efficiency was 76% and was observed to decrease over the 5 day operation/maintenance cycle of the module. The total water-soluble sulfate input to the scrubber amounted to approximately 1% of the total sulfur oxides and was composed of a 5:1 ratio of H₂SO₄ to particulate sulfate. The total sulfate scrubbing efficiency, averaging about 29%, was invariant with respect to SO₂ removal. The sulfate emissions measured in the scrubber exit gas consisted of about 85 % H₂SO₄ as a fine aerosol. Mass emissions of acid and particulate sulfate were calculated as 1730 Ib/hr and 305 Ib/hr, respectively.