Integration of novel hybrid composite discharge electrode with semi-pilot novel cross-flow electrostatic precipitator

ABSTRACT

Wet electrostatic precipitators (WESPs) are modern-era pollution control systems specifically designed to capture ultrafine particles as well as acid mist, highly resistive and sticky particles; however, this requires the use of expensive corrosion-resistant metal alloys. The work presented here is part of a continuing study at Ohio University aimed at reducing the cost of WESPs by using a novel combination of a polymer collector surfaces with a hybrid composite discharge electrode. In this study, a hybrid composite discharge electrode was tested, for the first time, inside a semi-pilot-scale experimental setup, with collection surfaces consists of a vertical array of strands. Particle laden gases were passed through this array of polymer ropes, which were kept wet by a small flow of water. The discharge electrodes were composite laminates of carbon fibers in a polymer matrix enclosing a metal mesh. The preliminary results showed that this new integrated system of composite discharge electrode and polymer collector surfaces can match or exceed the performance of a conventional metal alloy electrostatic precipitator (ESP) with metal discharge electrodes. There are additional advantages due to the system being compact, lightweight, and highly corrosion resistant.

Implications: This study focused on integrating and assessing performance of a novel hybrid composite electrode (HCE) inside semi-pilot novel cross-flow electrostatic precipitator at conditions typically observed in coal-fired power plant exhausts. The results were collected for particulate collection efficiencies and were compared with a rigid metal electrode. The HCE outperformed metal electrode by showing higher particulate collection efficiency. This result showcases substantial potential for these two new technologies (HCE and cross-flow system) as a substitute for conventional metal based wet ESPs.     

Fine particle migration and collection in a wet electrostatic precipitator

Electrostatic precipitation is considered as an effective technology for fine particle removal. A lab-scale wet electrostatic precipitator (ESP) with wire-to-plate configuration was developed to study particle migration and collection. The performance of the wet ESP was evaluated in terms of the corona discharge characteristics, total removal efficiency and fractional removal efficiency. The corona discharge characteristics and particle removal abilities of the wet ESP were investigated and compared with dry ESP. Particle removal efficiency was influenced by discharge electrode type, SO₂ concentration, specific collection area (SCA) and particle/droplet interaction. Results showed that the particle removal efficiency of wet ESP was elevated to 97.86% from 93.75% of dry ESP. Three types of discharge electrodes were investigated. Higher particle removal efficiency and larger migration velocity could be obtained with fishbone electrode. Particle removal efficiency decreased by 2.87% when SO₂ concentration increased from 0 ppm to 43 ppm as a result of the suppression of corona discharge and particle charging. The removal efficiency increased with higher SCA, but it changed by only 0.71% with the SCA increasing from 25.0 m²/(m³/s) to 32.5 m²/(m³/s). Meanwhile, the increasing of particle and droplet concentration was favorable to the particle aggregation and improved particle removal efficiency.

Implications: This work tends to study the particle migration and collection under spraying condition. The performance of a wet electrostatic precipitator (ESP) is evaluated in terms of the corona discharge characteristics, total particle removal efficiency, and fractional particle removal efficiency. The effects of water droplets on particle removal, especially on removal of particles with different sizes, is investigated. The optimization work was done to determine appropriate water consumption, discharge electrode type, and specific collection area, which can provide a basis for wet ESP design and application.     

Experimental study of cross-flow wet electrostatic precipitator

This paper reports development and testing of a novel cross-flow wet electrostatic precipitator (WESP), recently patented at Ohio University, that utilizes vertical columns of permeable material in the form of polypropylene ropes placed in a cross-flow configuration within a flue gas stream. The cross-flow design has large surface area, which provides scrubbing action; therefore, it has the potential for removing multiple pollutants, including particulates, gases, vapors, and mists. In this new method, the ropes are kept wet by the liquid (water) introduced from the top of the cells running downward on the ropes by capillary action, making the permeable materials act as the ground electrode for capturing particles from the flue gas. Preliminary testing has shown an efficiency of well above 80% using two cells and three sets of discharge electrodes. Since the material of construction is primarily corrosion-resistant polymeric material, both weight and cost reductions are expected from this new design.

Implications: The newly invented cross-flow WESP exhibit particulate collection efficiency of well above 80% when introduced in particulate-laden exhaust flow. This value was obtained using a two cells and three discharge electrodes configuration. The electric field strength has a substantial effect on the collection efficiency. Also, the pressure drop test results indicate that there is a potential to increase the collection area, which, in turn, will increase the collection efficiency further.     

Inhibition and promotion of trace pollutant adsorption within electrostatic precipitators

Among the technologies available for reducing mercury emissions from coal-fired electric utilities is the injection of a powdered sorbent, often some form of activated carbon, into the flue gas upstream of the particulate control device, most commonly an electrostatic precipitator (ESP). Detailed measurements of mercury removal within ESPs are lacking due to the hazardous environment they pose, increasing the importance of analysis and numerical simulation in understanding the mechanisms involved. Our previous analyses revealed that mercury adsorption by particles suspended in the gas and mercury adsorption by particles collected on internal ESP surfaces are not additive removal mechanisms but rather are competitive. The present study expands on this counterintuitive finding. Presented are results from numerical simulations reflecting the complete range of possible mass transfer boundary conditions representing mercury adsorption by the accumulated dust cake covering internal ESP collection electrodes. Using the two mercury removal mechanisms operating concurrently and interdependently always underperforms the sum of the two mechanisms’ individual contributions.

Implications: The dual use of electrostatic precipitators (ESPs) for particulate removal and adsorption of trace gaseous pollutants such as mercury is increasing as mercury regulations become more widespread. Under such circumstances, mercury adsorption by particles suspended in the gas and mercury adsorption by particles collected on internal ESP surfaces are competitive. Together, the two mercury removal mechanisms always underperform the sum of their two independent contributions. These findings can inform strategies sought by electric utilities for reducing the usage costs of mercury sorbents.     

Decomposition of volatile organic compounds using corona discharge plasma technology

This paper explores the application of corona plasma technology as a tool in treatment of volatile organic compounds (VOCs). The review introduces the principle of corona discharge and describes the characteristics of plasma, especially of various corona plasma reactors. By summarizing the main features of such reactors, this paper provides a brief background to different power sources and reactor configurations and their application to VOC treatment design. Considering chlorinated compounds, benzene series and sulfur compounds, this paper reveals the probable mechanism of corona plasma in VOC degradation. Additionally, the effects of numerous technical parameters – such as reactor structure, shape and materials of electrodes, and humidity – are analyzed comprehensively. Product distribution, energy efficiency and economic benefits are invoked as factors to evaluate the performance of VOC degradation. Finally, the practical application of corona plasma and its advantages are briefly introduced. The review aims to illustrate the enormous potential of corona plasma technology in the treatment of VOCs, and identifies future directions.

Implications: This paper comprehensively describes the principle, characteristics, research progress and engineering application examples of the degradation of volatile organics by corona discharge plasma, to provide a theoretical basis for the industrial application of this process.     

Wetting properties and performance test of modified rigid collector in wet electrostatic precipitators

The fine particles are considered a significant pollution problem. The wet electrostatic precipitators (ESPs) have advantages of efficient collection of the fine particles with lower pressure drop and eliminating reentrainment. The wetting properties of the collector surfaces have significantly important effect on wet ESPs’ stable and secure operation. The modified rigid collector (MRC) was modified by coating specific vinyl ester resin composites and loose glass fiber cloth over the conventional carbon steel in a certain way. The rigid collector surfaces before and after modification had been characterized by scanning electron microscopy (SEM) and interface tensiometer. The effect of operating temperatures on the wetting properties of the rigid collector surfaces before and after modification was investigated. The temperature range was 40~90 °C, and the wetting properties contained liquid holdup, surface flow rate, film rate, average film thickness, and critical saturation time. The modified rigid collector surface exhibited excellent wetting properties at the operating temperatures. The fine particles collection performance compared among the MRC, the conventional rigid collector (CRC), and the flexible collector (FC) in the wet ESPs was investigated. The effects of the applied voltage, the water film, corona power, and the specific collecting area on the fine particles collection were evaluated. The modified rigid collector provided high fine particles collection effect with lower energy and water consumption.

Implications: To improve the submicron particles collection efficiency and decrease energy and water consumption, the formation of uniform water film over the collector surfaces has been widely studied. The modified rigid collector was modified by coating specific vinyl ester resin composites and loose glass fiber cloth (ERGF) over the conventional carbon steel (CCS) in a certain way. The modified rigid collector surface exhibited excellent wetting properties. The wet ESPs by the modified rigid collector exhibited significantly higher particles collection efficiency than by the conventional rigid collector.     

Membrane-based wet electrostatic precipitation

Emissions of fine particulate matter, PM2.5, in both primary and secondary form, are difficult to capture in typical dry electrostatic precipitators (ESPs). Wet (or water-based) ESPs are well suited for collection of acid aerosols and fine particulates because of greater corona power and virtually no re-entrainment. However, field disruptions because of spraying (misting) of water, formation of dry spots (channeling), and collector surface corrosion limit the applicability of current wet ESPs in the control of secondary PM2.5. Researchers at Ohio University have patented novel membrane collection surfaces to address these problems. Water-based cleaning in membrane collectors made of corrosion-resistant fibers is facilitated by capillary action between the fibers, maintaining an even distribution of water. This paper presents collection efficiency results of lab-scale and pilot-scale testing at FirstEnergy's Bruce Mansfield Plant for the membrane-based wet ESP. The data indicate that a membrane wet ESP was more effective at collecting fine particulates, acid aerosols, and oxidized mercury than the metal-plate wet ESP, even with approximately 15% less collecting area.     

Purification characteristics of fine particulate matter treated by a self-flushing wet electrostatic precipitator equipped with a flexible electrode

A self-flushing wet electrostatic precipitator was developed to investigate the removal performance for fine particles. Flexible material (polypropylene, 840A) and carbon steel in the form of a spiked band were adopted as the collection plate and discharge electrode, respectively. The particle concentration, morphology, and trace-element content were measured by electric low-pressure impactor, scanning electron microscope, and energy-dispersive x-ray spectroscopy, respectively, before and after the electrostatic precipitator. With increasing gas velocity, the collection efficiency of fine particles (up to 0.8 μm in diameter) increased, while it decreased for particles with diameters larger than 0.8 μm. Increasing the dust inlet concentration increased the collection efficiency up to a point, from which it then declined gradually with further increases in the inlet concentration. The particulate matter after the wet electrostatic precipitator showed different degrees of agglomeration. The collection efficiency of trace elements within PM₁₀ was less than that of the PM₁₀ itself. Notably, the water consumption in the current setup was significantly lower than for other treatment processes of comparable collection efficiencies.

Implications: Wet electrostatic precipitators, as fine filtration equipment, were generally applicable to coal-fired plants to reduce PM_2.5 emissions in China. However, high energy consumption and unstable operation, such as water usage and spray washing directly in the electric field, seriously restricted the further development. The utilization of self-flushing wet electrostatic precipitator can solve these problems to some extent.     

Performance evaluation of novel wet vibrational precipitator

This study reports the development, construction, and initial testing of a novel vibrational precipitator (VP), patented at Ohio University in 2016, that uses vibrating metal cables with water running over them to capture particulate matter in an exhaust stream. Unlike traditional electrostatic precipitators relying on electric energy to capture particles, this new system uses the concept of vortex shedding to produce vibrations in vertical cables running perpendicular to an exhaust stream. Collisions between particles in the exhaust stream and these vibrating cables cause the particles to land onto a thin film of flowing water around the cables, which carries the particles downward for collection and removal. Initial tests with air containing particulates of 3 micron average particle size show capture efficiencies up to 54% using U.S. Environmental Protection Agency (EPA) Method 5 to measure the particulate concentrations at the upstream and downstream of a VP comprising 8 cells. These results show that this system, without consuming any electric energy, has a significant potential to be a simple and cost-effective way to treat particle-laden exhaust gases.

Implications: In this work, for the first time, a novel precipitator is investigated that captures particles without using any particle charging and (hence) any electricity. The capture mechanism is governed by vibrations of collection electrodes, which are vertical steel cables wetted through continuous flow of water. Without any discharge electrodes, electrode suspension mechanism, and ability of the system to be installed in existing ducts, the novel precipitator becomes a simple chamber housing containing multiple collection electrode cells. The preliminary results show that this new technology can achieve net particulate matter capture efficiency of 54%. This paves a pathway forward for reducing capital and operating cost of air pollution control systems.     

Investigation of aerosol and gas emissions from a coal-fired power plant under various operating conditions

The concentrations of fine particles and selected gas pollutants in the flue gas entering the stack were measured under several common operation modes in an operating coal power plant producing electricity. Particle size distributions in a diameter range from 10 nm to 20 μm were measured by a scanning mobility particle sizer (SMPS), and the flue gas temperature and concentrations of CO₂ and SO₂ were monitored by a continuous emission monitoring system (CEMS). During the test campaign, five plant operating modes were studied: soot blowing, bypass of flue-gas desulfurization (FGD), reheat burner operating at 0% (turned off), 27%, and 42% (normal condition) of its full capacity. For wet and dry aerosols, the measured mode sizes were both around 40 nm, but remarkable differences were observed in the number concentrations (#/cm³, count per square centimeter). A prototype photoionizer enhanced electrostatic precipitator (ESP) showed improved removal efficiency of wet particles at voltages above +11.0 kV. Soot blowing and FGD bypass both increased the total particle number concentration in the flue gas. The temperature was slightly increased by the FGD bypass mode and varied significantly as the rating of reheat burner changed. The variations of CO₂ and SO₂ emissions showed correlations with the trend of total particle number concentration possibly due to the transitions between gas and particle phases. The results are useful in developing coal-fired power plant operation strategies to control fine particle emissions and developing amine-based CO₂ capture technologies without operating and environmental concerns associated with volatile amine emissions.

Implications: The measurement of the fine particle size distributions in the exhaust gas under several common operating conditions of a coal-fired power plant revealed different response relations between aerosol number concentration and the operating condition. A photo-ionizer enhanced ESP was demonstrated to capture fine particles with higher efficiency compared to conventional ESPs, and the removal efficiency increased with the applied voltage. The characteristic information of aerosols and main gaseous pollutants in the exhaust gas is extremely important for developing and deploying CO₂ scrubbers, whose amine emissions and operating effectiveness depends greatly on the upstream concentrations of fine particles, SO₂, from the power plant.     

Energy consumption and energy-saving potential analysis of pollutant abatement systems in a 1000-MW coal-fired power plant

Pollutant abatement systems are widely applied in the coal-fired power sector, and the energy consumption is considered an important part of the auxiliary power. An energy consumption analysis and assessment model of pollutant abatement systems in a power unit was developed based on the dynamic parameters and technology. The energy consumption of pollutant abatement systems in a 1000-MW coal-fired power unit that meets the ultra-low emission limits and the factors of operating parameters, including unit load and inlet concentration of pollutants, on the operating power were analyzed. The results show that the total power consumption of the pollutant abatement systems accounted for 1.27% of the gross power generation during the monitoring period. The wet flue gas desulfurization (WFGD) system consumed 67% of the rate, whereas the selective catalytic reduction (SCR) and electrostatic precipitator (ESP) systems consumed 8.9% and 24.1%, respectively. The power consumption rate of pollutant abatement systems decreased with the increase of unit load and increased with the increase of the inlet concentration of pollutants. The operation adjustment was also an effective method to increase the energy efficiency. For example, the operation adjustment of slurry circulation pumps could promote the energy-saving operation of the WFGD system.

Implications: The application of pollutant abatement technologies increases the internal energy consumption of the power plant, which will lead to an increase of power generation costs. The real-time energy consumption of the different pollutant abatement systems in a typical power unit is analyzed based on the dynamic operating data. Further, the influence of different operating parameters on the operating power of the system and the possible energy-saving potential are analyzed.     

Effects of aeration frequency on leachate quality and waste in simulated hybrid bioreactor landfills

Research has been conducted to investigate the effects of daily aeration frequency on leachate quality and waste settlement in simulated hybrid landfill bioreactors. Four laboratory-scale reactors were constructed and operated for about 10 months to simulate different bioreactor operations, including one anaerobic bioreactor and three hybrid bioreactors with different aeration frequencies (one, two, and four times per day). Chemical oxygen demand (COD) and biochemical oxygen demand (BOD₅) reduced more than 96% of the initial concentrations in all aerated bioreactors. The differences of COD and BOD₅ reductions among tested aeration frequencies were relatively small. For ammonia nitrogen, the higher aeration frequency (two or four times per day) resulted in the quicker reduction. Overall, the concentrations of heavy metals (Cr, Co, Cu, Mn, Ni, and Zn) decreased over time except Cd and Pb. The reduction of redox-sensitive metal concentrations (Mn, Co, Ni, and Cu) was greater in aerated bioreactors than in anaerobic bioreactor. Settlement of municipal solid waste (MSW) was enhanced with higher frequency of aeration events (four times per day).

Implications: In recent years, hybird bioreactor landfill technology has gained a lot of attention. Appropriate aeration rate is crucial for hybrid bioreactor operation, but few studies have been done and different results were obtained. Research was conducted to investigate the effects of daily aeration frequency on leachate quality and waste settlement. Results indicated that aeration can effectively accelerate waste stabilization and remove organic carbon concentration and total nitrogen in the leachate.     

Issues and Trends in Electrostatic Precipitation Technology for U.S. Utilities

The pace and direction of electrostatic precipitator (ESP) technology evolution in the United States will be governed by two key forces. The first is new clean air legislation passed by the U.S. Congress and signed by President Bush on November 15,1990. This law requires electric utilities to further reduce SO₂ and NO_x emissions, which may impact particulate controls. In addition, very fine (< 10 micron) participates and potentially toxic trace emissions from utility power plants may be regulated. The second major factor is the expected upsurge in new plant construction beginning in the late 1990s. Together, these forces should define the performance requirements and market for new ESPs.

This paper identifies and briefly describes technologies that the Electric Power Research Institute (EPRI) is developing to help U.S. utilities meet these challenges cost-effectively. Among the technologies addressed are: advanced digital voltage controls, flue gas conditioning, intermittent energization, temperature-controlledprecharging (i.e., two-stage ESP), wide plate spacing, positive energization of corona electrodes for hot-side ESPs, and integration of conventional ESPs with pulse-jet baghouses.     

Mass transfer within electrostatic precipitators: trace gas adsorption by sorbent-covered plate electrodes

Varying degrees of mercury (Hg) capture have been reported within the electrostatic precipitators (ESPs) of coal-fired electric utility boilers. There has been some speculation that the adsorption takes place on the particulate-covered plate electrodes. This convective mass transfer analysis of laminar and turbulent channel flows provides the maximum potential for Hg adsorption by the plate electrodes within an ESP under those conditions. Mass transfer calculations, neglecting electrohydrodynamic (EHD) effects, reveal 65% removal of elemental Hg for a laminar flow within a 15-m-long channel of 0.2-m spacing and 42% removal for turbulent flow within a similar configuration. Both configurations represent specific collection areas (SCAs) that are significantly larger than conventional ESPs in use. Results reflecting more representative SCA values generally returned removal efficiencies of <20%. EHD effects, although potentially substantial at low Reynolds numbers, diminish rapidly with increasing Reynolds number and become negligible at typical ESP operating conditions. The present results indicate maximum Hg removal efficiencies for ESPs that are much less than those observed in practice for comparable ESP operating conditions. Considering Hg adsorption kinetics and finite sorbent capacity in addition to the present mass transfer analyses would yield even lower adsorption efficiencies than the present results. In a subsequent paper, the author addresses the mass transfer potential presented by the charged, suspended particulates during their collection within an ESP and the role they potentially play in Hg capture within ESPs.     

Public health and components of particulate matter: The changing assessment of black carbon

In 2012, the WHO classified diesel emissions as carcinogenic, and its European branch suggested creating a public health standard for airborne black carbon (BC). In 2011, EU researchers found that life expectancy could be extended four to nine times by reducing a unit of BC, vs reducing a unit of PM_2.5. Only recently could such determinations be made. Steady improvements in research methodologies now enable such judgments.

In this Critical Review, we survey epidemiological and toxicological literature regarding carbonaceous combustion emissions, as research methodologies improved over time. Initially, we focus on studies of BC, diesel, and traffic emissions in the Western countries (where daily urban BC emissions are mainly from diesels). We examine effects of other carbonaceous emissions, e.g., residential burning of biomass and coal without controls, mainly in developing countries.

Throughout the 1990s, air pollution epidemiology studies rarely included species not routinely monitored. As additional PM_2.5. chemical species, including carbonaceous species, became more widely available after 1999, they were gradually included in epidemiological studies. Pollutant species concentrations which more accurately reflected subject exposure also improved models.

Natural “interventions” - reductions in emissions concurrent with fuel changes or increased combustion efficiency; introduction of ventilation in highway tunnels; implementation of electronic toll payment systems – demonstrated health benefits of reducing specific carbon emissions. Toxicology studies provided plausible biological mechanisms by which different PM species, e.g., carbonaceous species, may cause harm, aiding interpretation of epidemiological studies.

Our review finds that BC from various sources appears to be causally involved in all-cause, lung cancer, and cardiovascular mortality, morbidity, and perhaps adverse birth and nervous system effects. We recommend that the U.S. EPA rubric for judging possible causality of PM_2.5. mass concentrations, be used to assess which PM_2.5. species are most harmful to public health.

Implications: Black carbon (BC) and correlated co-emissions appear causally related with all-cause, cardiovascular, and lung cancer mortality, and perhaps with adverse birth outcomes and central nervous system effects. Such findings are recent, since widespread monitoring for BC is also recent. Helpful epidemiological advances (using many health relevant PM_2.5 species in models; using better measurements of subject exposure) have also occurred. “Natural intervention” studies also demonstrate harm from partly combusted carbonaceous emissions. Toxicology studies consistently find biological mechanisms explaining how such emissions can cause these adverse outcomes. A consistent mechanism for judging causality for different PM_2.5 species is suggested.

A list of acronyms will be found at the end of the article.     

Integration of a nonmetallic electrostatic precipitator and a wet scrubber for improved removal of particles and corrosive gas cleaning in semiconductor manufacturing industries

To remove particles in corrosive gases generated by semiconductor industries, we have developed a novel non-metallic, two-stage electrostatic precipitator (ESP). Carbon brush electrodes and grounded carbon fiber-reinforced polymer (CFRP) form the ionization stage, and polyvinyl chloride collection plates are used in the collection stage of the ESP The collection performance of the ESP downstream of a wet scrubber was evaluated with KC1, silica, and mist particles (0.01-10 pm), changing design and operation parameters such as the ESP length, voltage, and flow rate. A long-term and regeneration performance (12-hr) test was conducted at the maximum operation conditions of the scrubber and ESP and the performance was then demonstrated for 1 month with exhaust gases from wet scrubbers at the rooftop of a semiconductor manufacturing plant in Korea. The results showed that the electrical and collection performance of the ESP (16 channels, 400x400 mm2) was maintained with different grounded plate materials (stainless steel and CFRP) and different lengths of the ionization stage. The collection efficiency of the ESP at high air velocity was enhanced with increases in applied voltages and collection plate lengths. The ESP (16 channels with 100 mm length, 400x400 mm2x540 mm with a 10-mm gap) removed more than 90% of silica and mistparticles with 10 and 12 kV applied to the ESPat the air velocity of 2 m/s and liquid-to-gas ratio of 3.6 L/m3. Decreased performance after 13 hours ofcontinuous operation was recovered to the initial performance level by 5 min of water washing. Moreover during the 1-month operation at the demonstration site, the ESP showed average collection efficiencies of 97% based on particle number and 92% based on total particle mass, which were achieved with a much smaller specific corona power of 0.28 W/m3/hr compared with conventional ESPs.     

Removal characteristics of sulfuric acid aerosols from coal-fired power plants

With increasing attention on sulfuric acid emission, investigations on the removal characteristics of sulfuric acid aerosols by the limestone gypsum wet flue gas desulfurization (WFGD) system and the wet electrostatic precipitator (WESP) were carried out in two coal-fired power plants, and the effects of the WFGD scrubber type and the flue gas characteristics were discussed. The results showed that it was necessary to install the WESP device after desulfurization, as the WFGD system was inefficient to remove sulfuric acid aerosols from the flue gas. The removal efficiency of sulfuric acid aerosols in the WFGD system with double scrubbers ranged from 50% to 65%, which was higher than that with a single scrubber, ranging from 30% to 40%. Furthermore, the removal efficiency of WESP on the sulfuric acid aerosols was from 47.9% to 52.4%. With increased concentrations of SO₃ and particles in the flue gas, the removal efficiencies of the WFGD and the WESP on the sulfuric acid aerosols were increased.

Implications: Investigations on removal of sulfuric acid aerosols by the WFGD and the WESP in the power plants were aimed at the control of sulfuric acid emission. The results showed that the improvement of the WFGD system was beneficial for the reduction of sulfuric acid emission, while the WESP system was essential to control the final sulfuric acid aerosol concentration.     

Validation of a new method for measuring and continuously monitoring the efficiency of industrial flares

A new method has been developed for a direct and remote measurement of industrial flare combustion efficiency (CE). The method is based on a unique hyper-spectral or multi-spectral Infrared (IR) imager which provides a high frame rate, high spectral selectivity and high spatial resolution. The method can be deployed for short-term flare studies or for permanent installation providing real-time continuous flare CE monitoring.

In addition to the measurement of CE, the method also provides a measurement for level of smoke in the flare flame regardless of day or night. The measurements of both CE and smoke level provide the flare operator with a real-time tool to achieve “incipient smoke point” and optimize flare performance.

The feasibility of this method was first demonstrated in a bench scale test. The method was recently tested on full scale flares along with extractive sampling methods to validate the method. The full scale test included three types of flares – steam assisted, air assisted, and pressure assisted. Thirty-nine test runs were performed covering a CE range of approximately 60-100%. The results from the new method showed a strong agreement with the extractive methods (r²=0.9856 and average difference in CE measurement=0.5%).

Implications: Because industrial flares are operated in the open atmosphere, direct measurement of flare combustion efficiency (CE) has been a long-standing technological challenge. Currently flare operators do not have feedback in terms of flare CE and smoke level, and it is extremely difficult for them to optimize flare performance and reduce emissions. The new method reported in this paper could provide flare operators with real-time data for CE and smoke level so that flare operations can be optimized. In light of EPA’s focus on flare emissions and its new rules to reduce emissions from flares, this policy-relevant development in flare CE monitoring is brought to the attention of both the regulating and regulated communities.     

The dissolution kinetics of industrial brine sludge wastes from a chlor-alkali industry as a sorbent for wet flue gas desulfurization (FGD)

The disposal of industrial brine sludge waste (IBSW) in chlor-alkali plants can be avoided by utilization of IBSW as a sorbent in wet flue gas desulfurization (FGD). The shrinking core model was used to determine the dissolution kinetics of IBSW, which is a vital step in wet FGD. The effects of solid-to-liquid ratio (m/v), temperature, pH, particle size, and stirring speed on the conversion and dissolution rate constant are determined. The conversion and dissolution rate constant decreases as the pH, particle size, and solid-to-liquid ratio are increased and increases as the temperature, concentration of acid, and stirring speed are increased. The sorbents before and after dissolution were characterized using x-ray fluorescence (XRF), x-ray diffraction (XRD), and scanning electron microscopy (SEM). An activation energy of 7.195 kJ/mol was obtained and the product layer diffusion model was found to be the rate-controlling step.

Implications: The use of industrial brine sludge waste as an alternative sorbent in wet flue gas desulfurization can reduce the amounts of industrial wastes disposed of in landfills. This study has proved that the sorbent can contain up to 91% calcium carbonate and trace amounts of sulfate, magnesium, and so on. This can be used as new sorbent to reduce the amount of sulfur dioxide in the atmosphere and the by-product gypsum can be used in construction, as a plaster ingredient, as a fertilizer, and for soil conditioning. Therefore, the sorbent has both economic and environmental benefits.     

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.