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.     

Reducing Pressure Drop in a Baghouse Using Flow Distributors

ABSTRACT

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.     

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.     

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.     

Filtration Properties of Fly Ash from Fluidized Bed Combustion

Some of the features of the fluidized-bed combustion (FBC) process have a direct bearing on the particulate properties that most strongly influence filtering pressure drop. A laboratory program was conducted to experimentally determine the relative pressure drop characteristics of ashes from the TVA-EPRI 20-MW bubbling bed, atmospheric pressure FBC (AFBC) pilot plant and six pulverized-coal combustion (PC) units. The combined influences of measured particle and dust cake properties on filtering pressure drop were estimated with existing filtration theories. These theories predict a higher pressure drop for a dust cake produced with the AFBC ash than for one consisting of any of the PC ashes. Laboratory measurements were made of the flow resistance of idealized, simulated dust cakes to confirm these predictions. Field operating data from the fabric filters collecting some of the tested ashes were available to validate the laboratory results. The laboratory and field data show relatively good agreement. The AFBC ash must be treated as a special case for fabric filters, and careful selection of cleaning method and fabric must be made to minimize the inherently high pressure drop characteristics of this ash.     

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.     

Filtration CharacteristicsOf Fly Ash from a Pulverized Coal-Fired Power Plant

The operating characteristics of a pilot baghouse and the filtering characteristics of fly ash filtered from the flue gas of a pulverized coal-fired power plant were studied by techniques developed in the engineering research laboratories of the National Center for Air Pollution Control in Cincinnati. The permeability of the dust cake varied with the operating conditions of the baghouse in a way that significantly affects the pressure drop and power requirements of the system.     

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.     

Optimization of Height of Release of Air Pollutants

A number of key projects in the Environmental Protection Agency (EPA) particulate R&;D program having applicability to industry are presented. For electrostatic precipitators (ESP) there is presented the result of work on large diameter discharge electrodes which provide a decrease in penetration of up to a factor of 4 when compared to conventional small diameter electrodes. Also discussed is the multistage ESP which provides a collection efficiency that would require a collecting plate area 4 or 5 times larger with conventional ESP technology. The E-SOX technology makes use of the multistage concept to free up space in the ESP for SO₂ removals of up to 90%. Electrostatically augmented fabric filtration provides a reduction in pressure drop of about 5 0% as compared to conventional fabric filtration. Wind tunnel modeling of windbreaks for material storage piles indicates a potential for providing engineering design data that would allow significant emission reduction caused by wind erosion     

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.     

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.     

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.     

Control of Fly Ash from Conventional Coal-Fired Utility Boilers

This paper presents a detailed review and critical evaluation of current technologies as applied to fine particulate emissions from coal-fired utility boilers. Quantitative assessments of the capabilities of both conventional and novel air pollution control devices to meet three different performance standards—the present New Source Performance Standard (NSPS) of 0.03 Ib particulate/MBtu heat input, and standards of 0.05 and 0.1 Ib particulate/MBtu are included. Each of the three conventional devices (electrostatic precipitator, fabric filter baghouse, and wet scrubber) is compared and rated with respect to eight different performance categories. This information can be used to determine the relative effectiveness and attractiveness of these three control devices. Novel devices are compared and rated in the same manner, the conclusions from which may provide the research administrator with a guide for the selection of those novel devices which offer the best potential for commercialization.

The major conclusions of the investigation are: (1) The use of conventional scrubbers for fine particulate control on coal-fired utility boilers may no longer be feasible at the new NSPS of 0.03 Ib/MBtu. (2) At the old NSPS (0.1 Ib/MBtu) conventional electrostatic precipitators and baghouses were often competitive. For the new stricter standard, however, the baghouse generally is the more attractive alternative. (3) Novel devices appear to offer almost no hope for this particular application (at a commercial level) between now and 1985 and only little hope before 1990.     

Dust Deposit Profiles in a High Velocity Pulse-Jet Fabric Filter

Dust deposit profiles in a pilot-scale pulse-jet fabric filter were measured using a beta gauge. Fly ash was collected on polyester needled felt bags, and the dust profiles were measured after the test system was operated to equilibrium at superficial filtration velocities of 50, 75,100,125, and 150 mm/s. The profiles measured show that a large mass of dust is retained on the fabric of a pulse-jet filter when operated at high filtration velocities. This dust mass retention can be caused by two mechanisms: the failure to remove dust from the fabric during a cleaning pulse, and the redeposition of suspended dust onto the fabric after a cleaning pulse. The dust deposit measured at the highest test velocity was found to be much different from the deposits measured at all other velocities. The deposit found at 150 mm/s had almost twice the average areal density and was more evenly distributed than the deposits found at lower velocities.     

Characterization of activated carbon fiber filters for pressure drop, submicrometer particulate collection, and mercury capture

The use of activated carbon fiber (ACF) filters for the capture of particulate matter and elemental Hg is demonstrated. The pressure drop and particle collection efficiency characteristics of the ACF filters were established at two different face velocities and for two different aerosols: spherical NaCl and combustion-generated silica particles. The clean ACF filter specific resistance was 153 kg m-2 sec-1. The experimental specific resistance for cake filtration was 1.6 x 10(6) sec-1 and 2.4 x 10(5) sec-1 for 0.5- and 1.5-micron mass median diameter particles, respectively. The resistance factor R was approximately 2, similar to that for the high-efficiency particulate air filters. There was a discrepancy in the measured particle collection efficiencies and those predicted by theory. The use of the ACF filter for elemental Hg capture was illustrated, and the breakthrough characteristic was established. The capacity of the ACF filter for Hg capture was similar to other powdered activated carbons.     

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.     

Effect of Ammonia Injection on Fabric Filter Pressure Drop

Experiments have been carried out to assess the effect of ammonia injection upstream of a small-scale fabric filter which collects ash from the burning of coal in Australia. The ammonia injection resulted in an increase in the pressure drop across the filter. This was apparently due to an increase in the cohesivity of the ash, which made dislodgement during cleaning more difficult. There were some indications that the ammonia-conditioned ash formed a more porous dust cake during the filtration cycle.     

Fabric Filtration for Fly Ash Control

Economic projections and the growing experience with more diverse baghouse applications indicate that fabric filtration will become an even more popular type of control technology. While the fabric filter market shows signs of great promise now, an especially significant upturn is predicted within the next half dozen years when dry scrubbing becomes the primary process for combined S0₂ and par-ticulate control. In the interim, with more and more utility and industrial boilers gaining experience with baghouses, this control method can be expected to develop as an even more acceptable technique, especially on low S coal burning units. Nevertheless, the users stress the need for conservative planning and designing, giving extra care to start-up and maintenance procedures.     

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

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 variables that influence baghouse performance. A database was assembled including measured characteristics of coal and dustcake ash, and data describing operating parameters and performance of full-scale and pilotscale baghouses. Predictions of performance can be based on physical characteristics of the ash to be filtered (discussed in Part I of this article), as well as chemical characterizations of the ash, or empirical correlations with the alkali content of the source coal The effects of design and operational variables can be included in these predictions. Baghouse performance can be optimized by exercising proper operating practices and by selecting a filtering fabric and cleaning method matched to the cohesivity of the ash to be collected.