Closing Comments

“Industrial fabric filtration, the sleeping giant, is stirring. It appears that we are about to experience a new period of innovation and development similar to the one that occurred during the 1950’s.” The above remarks by Professor First, as presented in the Symposium, unerscore the renewed interest in filtration as a means for controlling submicron particulate emissions. Bur-chard and others pointed out the significance of fine particulate emissions, especially with regard to health effects and visibility degradation, and Walsh discussed the data required to employ fabric filters appropriately for particulate emission control.     

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.     

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.     

The Potential of Pulse-Jet Baghouses for Utility Boilers Part 3: Comparative Economics of Pulse-Jet Baghouse,Precipitators and Reverse-Gas Baghouses

Pulse-jet fabric filters (PJFFs) are widely used in U.S. industrial applications, and in both utility and industrial boilers abroad. Their smaller size and reduced cost relative to more conventional baghouses make PJFFs an attractive particulate control option for utility boilers. This article which is the third in a three-part series, compares the cost of PJFFs with electrostatic precipitators (ESPs) and reverse-gas baghouses (RGBs).

This article presents the capital, operating and maintenance (O&M), and level-ized costs for ESPs, RGBs and PJFFs. The particulate control equipment design and pricing are supplied by manufacturers of the control equipment. A comparison of costs for a base case 250-MW boiler indicates that the PJFF capital cost is 22 percent lower than the cost of an ESP with 400 SCA and 12-inch plate spacing; in addition the PJFF is 35 percent lower than the cost of an RGB. The levelized cost for a PJFF is about equal to the cost of the ESP but 14 percent lower than the cost of the RGB. Overall, the attractiveness of a PJFF versus an ESP depends on the coal type and the outlet emissions limit required. PJFF is favored when low-sulfur coal is fired due to the high-resistivity fly ash. Also, PJFF is favored as more stringent outlet emission rates are required.     

An extended self-organizing map network for modeling and control of pulse jet fabric filters

Pulse jet fabric filters (PJFFs) have become an attractive option of particulate collection utilities, because they can meet stringent particulate emission limits regardless of variation in operating conditions. Despite their wide applications, the present control algorithm for PJFFs can best be described as rudimentary. In this paper, a modeling and control strategy based on the local model network (LMN) is proposed. An extended self-organizing map (ESOM) network is developed to construct the LMN model of the filtration process using the filter's input-output data. Subsequently, these ESOM local models are incorporated into the design of local generalized predictive controllers (GPC), and the proposed controller design is obtained as the weighted sum of these local controllers. Simulation results show that the proposed controller design yields a better performance than both conventional GPC and proportional plus integral (PI) controllers yield.     

The Potential of Pulse-Jet Baghouses for Utility Boilers. Part 2: Performance of Pulse-Jet Fabric Filter Pilot Plants

Pulse-jet fabric filters (PJFFs) are widely used in U.S. industrial boiler applications and in utility and industrial boilers abroad. Their small size and reduced cost relative to more conventional reverse-gas baghouses makes the use of PJFFs appear to be an attractive particulate control option for utility boilers. This paper (Part 2 of a three-part series) summarizes the results of pilot PJFF studies sponsored by the Electric Power Research Institute at different utility sites in the United States. The purpose of these tests is to evaluate PJFF performance for U.S. fossil-fuel-fired applications. These data are also used to corroborate the results of a recent worldwide survey of PJFF user experience, as described in Part 1 of this series. Part 3 will provide a cost comparison of PJFFs to other particulate control options such as electrostatic precipitators and reverse-gas baghouses.     

An Extended Self-Organizing Map Network for Modeling and Control of Pulse Jet Fabric Filters

ABSTRACT

Pulse jet fabric filters (PJFFs) have become an attractive option of particulate collection utilities, because they can meet stringent particulate emission limits regardless of variation in operating conditions. Despite their wide applications, the present control algorithm for PJFFs can best be described as rudimentary. In this paper, a modeling and control strategy based on the local model network (LMN) is proposed. An extended self-organizing map (ESOM) network is developed to construct the LMN model of the filtration process using the filter's input-output data. Subsequently, these ESOM local models are incorporated into the design of local generalized predictive controllers (GPC), and the proposed controller design is obtained as the weighted sum of these local controllers. Simulation results show that the proposed controller design yields a better performance than both conventional GPC and proportional plus integral (PI) controllers yield.     

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.     

Capital and Operating Costs of Selected Air Pollution Control Systems — I

This is the first installment of a 4-part series which will present capital and operating costs of selected air pollution control systems. The objective of the Series is to identify the individual component costs so that realistic system cost estimates can be determined for any specific application. In Part I, cost estimating procedures and curves are provided to develop the equipment costs for electrostatic pre-cipitators, venturi scrubbers, fabric filters, incinerators, and adsorbers.     

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.     

Particle and substrate losses from Teflon® and quartz filters

Teflon® and quartz particulate matter samples were collected at two special study sites. In order to estimate changes in mass corresponding to the various filter handling operations (for TSP and PM₁₀ samples), changes in both controlled and shipped filter weights were monitored at predetermined stages of the filter handling process. The study data indicate that folding the quartz filters did not significantly change the filter mass even if the filter broke along the seam. A weight loss was noted following shipment of the TSP quartz filters but not the corresponding PM₁₀ quartz filters. Volatilization losses were also noted with the high volume samples collected at one city. Based on mass determinations, the quartz filters did not appear to be affected by passive artifact formation. No significant weight change occurred in the routine handling of the study dichotomous Teflon® filters. The results indicate that quartz and Teflon® filter media can be used in future particulate monitoring programs.     

Evaluation of catalyzed and electrically heated filters for removal of particulate emissions from diesel-A- and JP-8-fueled engines

In-service diesel engines are a significant source of particulate matter (PM) emissions, and they have been subjected to increasingly strict emissions standards. Consequently, the wide-scale use of some type of particulate filter is expected. This study evaluated the effect of an Engelhard catalyzed soot filter (CSF) and a Rypos electrically heated soot filter on the emissions from in-service diesel engines in terms of PM mass, black carbon concentration, particle-bound polycyclic aromatic hydrocarbon concentration, and size distribution. Both filters capture PM. The CSF relies on the engine's exhaust to reach the catalyst regeneration temperature and oxidize soot, whereas the electrically heated filter contains a heating element to oxidize soot. The filters were installed on several military diesel engines. Particle concentrations and compositions were measured before and after installation of the filter and again after several months of operation. Generally, the CSF removed at least 90% of total PM, and the removal efficiency improved or remained constant after several months of operation. In contrast, the electrical filters removed 44-69% of PM mass. In addition to evaluating the soot filters, the sampling team also compared the results of several real-time particle measurement instruments to traditional filter measurements of total mass.     

Types of Fabric Filter Installations

The basis for evaluating fabric filters is examined. Properly applied and maintained fabric filters perform at highly satisfactory efficiency levels.     

Evaluation of Catalyzed and Electrically Heated Filters for Removal of Particulate Emissions from Diesel-A- and JP-8-Fueled Engines

Abstract

In-service diesel engines are a significant source of particulate matter (PM) emissions, and they have been subjected to increasingly strict emissions standards. Consequently, the wide-scale use of some type of particulate filter is expected. This study evaluated the effect of an Engelhard catalyzed soot filter (CSF) and a Rypos electrically heated soot filter on the emissions from in-service diesel engines in terms of PM mass, black carbon concentration, particle-bound polycyclic aromatic hydrocarbon concentration, and size distribution. Both filters capture PM. The CSF relies on the engine's exhaust to reach the catalyst regeneration temperature and oxidize soot, whereas the electrically heated filter contains a heating element to oxidize soot. The filters were installed on several military diesel engines. Particle concentrations and compositions were measured before and after installation of the filter and again after several months of operation. Generally, the CSF removed at least 90% of total PM, and the removal efficiency improved or remained constant after several months of operation. In contrast, the electrical filters removed 44-69% of PM mass. In addition to evaluating the soot filters, the sampling team also compared the results of several real-time particle measurement instruments to traditional filter measurements of total mass.     

Relationship of Particulate Control,SO2 Removal,and Waste Management

Results with the EPRI 2.5 MW(e) Integrated Environmental Control Pilot Plant (IECPP) indicate the interrelationship of particulate penetration, SO₂ scrubber operation, waste production, and waste properties. Tests compared a fabric filter/wet scrubber and ESP/wet scrubber, the latter operated to simulate 1979 New Source Performance Standards (NSPS), 1971 NSPS, and pre-NSPS ESP units. Tests were conducted with low-sulfur coal producing a flue gas concentration of400ppm; flue gas spiking could be used to increase SO₂ to 2000 ppm. Scrubber waste was dewatered in a thickener and vacuum belt filter (to 55 percent solids content), and mixed with fly ash. The pilot SO₂ scrubber—when preceded by an ESP and forced to operate in zero-discharge—captured less SO₂ than when preceded by a fabric filter. Also, scrubber operation with the ESP produced a greater quantity of waste with difficult handling characteristics, as compared to operation with the fabric filter. These difficulties occurred with particulate penetration above 0.10 lb/MBtu, which could reduce reagent utilization to 80percent. These results are attributable to inhibited limestone dissolution due to accumulation of an aluminum/fluoride compound. For both lowsulfur and simulated high-sulfur test conditions, allowing wastewater discharge to purge aluminum/fluoride content restored performance to design levels. Particulate control efficiency also affected solid waste physical properties. The fabric filter/wet scrubber produced the lowest solid waste permeability (10^?8 cm/s). ESP operation at 1979 NSPS and pre-1971 NSPS ESPs increased solid waste permeability to 10^?7 and 10^?6 cm/s, respectively. These results are meaningful for SO₂ scrubbers both for new plants and for retrofit to units with pre-NSPS ESPs, and could become significant with the increasing trend to restricted water discharge.     

Single-Stage Dewatering of FGD Waste

The Escalante Unit No. 1 flue gas desulfurization (FGD) waste slurry dewatering system represents the first domestic utility to deviate from the typical industry two-stage dewatering system design. Evaluations conducted during the design phase compared three dewatering options: 1) thickener in series with vacuum filters, 2) thickener in series with centrifuges, and 3) centrifuges with no thickener. The evaluation showed that centrifuges with no thickener (one stage) could significantly reduce capital costs. Coupled with capital costs, this option also decreases operation and maintenance costs, reduces the complexity of the system, saves a considerable amount of space, and centralizes the FGD and dewatering systems within one building. This paper describes the evaluation that took place during the design phase of the project comparing the three dewatering options. Operational data for the first year of operation are presented, and operating and maintenance costs are discussed and compared with conventional two-stage dewatering systems.     

A Strategy for Reduction of Particulate Emissions in the Boston Area

Initial implementation plans provided for particulate reduction largely through the imposition of emission limitations on industrial processes, large steam generators, and solid waste disposal, requiring, in turn, application of control equipment for compliance. In many urban areas, this approach is not adequate to achieve the secondary air quality standards so that a more general strategy must be employed. Such strategy may include restrictions on fuel burning, combustion equipment, maintenance programs, utility steam distribution, etc. The potential abatement achievable through such strategies is described using Boston as a case study. Cost and technical factors associated with each strategy are discussed.     

Deriving fuel-based emission factor thresholds to interpret heavy-duty vehicle roadside plume measurements

Remote sensing devices have been used for decades to measure gaseous emissions from individual vehicles at the roadside. Systems have also been developed that entrain diluted exhaust and can also measure particulate matter (PM) emissions. In 2015, the California Air Resources Board (CARB) reported that 8% of in-field diesel particulate filters (DPF) on heavy-duty (HD) vehicles were malfunctioning and emitted about 70% of total diesel PM emissions from the DPF-equipped fleet. A new high-emitter problem in the heavy-duty vehicle fleet had emerged. Roadside exhaust plume measurements reflect a snapshot of real-world operation, typically lasting several seconds. In order to relate roadside plume measurements to laboratory emission tests, we analyzed carbon dioxide (CO₂), oxides of nitrogen (NO_X), and PM emissions collected from four HD vehicles during several driving cycles on a chassis dynamometer. We examined the fuel-based emission factors corresponding to possible exceedances of emission standards as a function of vehicle power. Our analysis suggests that a typical HD vehicle will exceed the model year (MY) 2010 emission standards (of 0.2 g NO_X/bhp-hr and 0.01 g PM/bhp-hr) by three times when fuel-based emission factors are 9.3 g NO_X/kg fuel and 0.11 g PM/kg using the roadside plume measurement approach. Reported limits correspond to 99% confidence levels, which were calculated using the detection uncertainty of emissions analyzers, accuracy of vehicle power calculations, and actual emissions variability of fixed operational parameters. The PM threshold was determined for acceleration events between 0.47 and 1.4 mph/sec only, and the NO_X threshold was derived from measurements where after-treatment temperature was above 200°C. Anticipating a growing interest in real-world driving emissions, widespread implementation of roadside exhaust plume measurements as a compliment to in-use vehicle programs may benefit from expanding this analysis to a larger sample of in-use HD vehicles.

Implications: Regulatory agencies, civil society, and the public at large have a growing interest in vehicle emission compliance in the real world. Leveraging roadside plume measurements to identify vehicles with malfunctioning emission control systems is emerging as a viable new and useful method to assess in-use performance. This work proposes fuel-based emission factor thresholds for PM and NOx that signify exceedances of emission standards on a work-specific basis by analyzing real-time emissions in the laboratory. These thresholds could be used to prescreen vehicles before roadside enforcement inspection or other inquiry, enhance and further develop emission inventories, and potentially develop new requirements for heavy-duty inspection and maintenance (I/M) programs, including but not limited to identifying vehicles for further testing.     

Real-world vehicle emissions: a summary of the Eleventh Coordinating Research Council On-Road Vehicle Emissions Workshop

The Coordinating Research Council (CRC) held its eleventh workshop in March 2001, focusing on results from the most recent real-world vehicle emissions research. We summarize the presentations from researchers engaged in improving our understanding of the contribution of mobile sources to ambient air quality and emission inventories. Participants in the workshop discussed efforts to improve mobile source emission models and emission inventories, the role of on-board diagnostic (OBD) systems in inspection and maintenance (I/M) programs, particulate matter (PM) emissions, contributions of diesel vehicles to the emission inventory, on-road emissions measurements, fuel effects, unregulated emissions, and microscale and modal emission models, as well as topics for future research.     

Engineering and Economic Considerations In Fabric Filtration

The basic engineering and economic factors relative to fabric filtration systems are reviewed. Fabrication and erection costs, and maintenance costs are then discussed in greater depth.