Air Pollution Control Systems & Devices

(Particulate Control)
• Considering factors
• Control Equipment
+ Control Equip. dependent upon particle characteristics such
as physical form of particulates (solid/liquid), particle size
and distribution, density and porosity, shape (spheres, fibres,
planar)
+ Equip. of three types – Gravitational and inertial collectors,
electrostatic precipitators, filters
 Gravitational Settling Chambers
• Operating temperature – 1000 deg.C
• Applications – precleaners for removing dry dust produced by
grinding in cement and lime kilns, grain elevators, rock crushers,
thermal coal dryers, furnaces
• Dust particle size - > 50 mm
• One of the first devices to control particulate emission
• Types – Simple expansion Chamber; Multi-tray settling chamber
• Force – Gravitational
• Once the horizontal gas velocity is reduced, large particles can be
overcome by gravity and fall into the hopper
• Typical horizontal velocity range of 0.3 to 3.0 m/s
 Gravitational Settling Chamber

 Expansion chamber
 Gravitational Settling Chamber
Howard Settling Chamber (multiple tray)
 Gravitational Settling Chamber
•Baffle Chamber
 Gravitational Settling Chamber

•Chamber Dimensions
 Gravitational Settling Chambers

• Settling chambers have high collection efficiency

• for low gas velocities,
• high terminal settling velocities, and
• large ratio of chamber length to height
• A large L/H ratio ensures a long residence time and short vertical
distance for the particle to travel to be collected
• Settling chambers are characterized by low capital costs and low
pressure drop
• They can be used under temperature (~ 1000 deg.C) and pressure
extremes (~100 atm.)
 Cyclones
• Types of designs
• Reverse flow or straight through
• Flue Gas Entry points – tangential, Scroll and Swirl vane
• Gas Flow rates – 50 –50,000 m3/hr
• Pressure drop – 0.5 to 0.8 inches in water
• Operating temperatures - ~1000 deg.C
• Applications – Cement and lime kilns, furnaces, milling operations,
power drying processes
• Dust particle sizes - > 5mm
• Dust concentration - > 2000g/m3
• Cyclones are efficient in removing large particles but are not as
efficient with smaller particles. For this reason, they are used with
other particulate control devices.
Cyclones
Single-cyclone separators create a
dual vortex to separate coarse from
fine dust. The main vortex spirals
downward and carries most of the
coarser dust particles. The inner
vortex, created near the bottom of the
cyclone, spirals upward and carries
finer dust particles.
Cyclones

• Multiple-cyclone separators, also

known as multiclones, consist of a

number of small-diameter cyclones,

operating in parallel and having a

common gas inlet and outlet.

• Multi-clones operate on the same

principle as cyclones--creating a

main downward vortex and an

ascending inner vortex.

 Cyclones
• Multiclones are more efficient than single cyclones because they are
longer and smaller in diameter.
• The longer length provides longer residence time while the smaller
diameter creates greater centrifugal force. These two factors result
in better separation of dust particulates.
• The pressure drop of multiclone collectors is higher than that of
single-cyclone separators.
 Cyclones
• Cyclones provide a low-cost, low-maintenance method of
removing larger particulates from a gas stream.
• The general principle of inertia separation is that the particulate-
laden gas is forced to change direction.
• As gas changes direction, the inertia of the particles causes them
to continue in the original direction and be separated from the gas
stream.
• The walls of the cyclone narrow toward the bottom of the unit,
allowing the particles to be collected in a hopper.
• The cleaner air leaves the cyclone through the top of the chamber,
flowing upward in a spiral vortex, formed within a downward
moving spiral.
 Cyclones
• Gas Flow Patterns
• The air flow pattern in a cyclone rotational field is
characterized by three velocity components such as
• Tangential
• Radial
• Axial
• After the air stream enters the cyclone, it will spiral downward
because of centrifugal and frictional forces. In the outer vortex,
the total air flow velocity consists of all the above three velocity
components
 Cyclones
• Gas Flow Patterns
• The tangential velocity is the dominant velocity component. It
also determines the centrifugal force applied to the air stream.
• The tangential velocity is the dominant velocity component. It
also determines the centrifugal force applied to the air stream.
• The tangential velocity increases with the decreasing of the
rotational radius in the outer vortex. It increases to the
maximum at the boundary of the outer vortex and inner vortex.
• In the inner vortex the tangential velocity decreases as the
rotational radius decrease.
 Cyclones
• Gas Flow Patterns
• The tangential velocity is the dominant
velocity component. It also determines
the centrifugal force applied to the air
stream.
• The tangential velocity increases with the
decreasing of the rotational radius in the
outer vortex. It increases to the maximum
at the boundary of the outer vortex and
inner vortex.
• In the inner vortex the tangential velocity
decreases as the rotational radius
decrease.
 Fabric Collectors
• Commonly known as baghouses,
fabric collectors use filtration to
separate dust particulates from
dusty gases.
• They are one of the most efficient
and cost effective types of dust
collectors available and can
achieve a collection efficiency of
more than 99% for very fine
particulates.
• Dust-laden gases enter the
baghouse and pass through fabric
bags that act as filters.
• The bags can be of woven or
felted cotton, synthetic, or glass-
fiber material in either a tube or
envelope shape
 Fabric Collectors
• The high efficiency of these collectors is due to the dust cake
formed on the surfaces of the bags. The fabric primarily
provides a surface on which dust particulates collect through the
following four mechanisms:
• Inertial Collection - Dust particles strike the fibers placed
perpendicular to the gas-flow direction instead of changing
direction with the gas stream.
• Interception - Particles that do not cross the fluid streamlines
come in contact with fibers because of the fiber size.
• Brownian Movement - Submicron particles are diffused,
increasing the probability of contact between the particles and
collecting surfaces.
• Electrostatic Forces - The presence of an electrostatic charge
on the particles and the filter can increase dust capture.
 Fabric Collectors
• As classified by cleaning method, three common types of
baghouses are -
• Mechanical shaker
• Reverse air
• Reverse jet
 Fabric Collectors
• Mechanical Shaker
• In mechanical-shaker baghouses,
tubular filter bags are fastened onto a
cell plate at the bottom of the baghouse
and suspended from horizontal beams
at the top.
• Dirty gas enters the bottom of the
baghouse and passes through the filter,
and the dust collects on the inside
surface of the bags.
• Cleaning a mechanical-shaker
baghouse is accomplished by shaking
the top horizontal bar from which the
bags are suspended.
• Vibration produced by a motor-driven
shaft and cam creates waves in the
bags to shake off the dust cake.
 Fabric Collectors
• Reverse Air
• In reverse-air baghouses, the bags are
fastened onto a cell plate at the bottom of
the baghouse and suspended from an
adjustable hanger frame at the top.
• Reverse-air baghouses are
compartmentalized to allow continuous
operation.
• Bags are cleaned by injecting clean air into
the dust collector in a reverse direction,
which pressurizes the compartment.
• The pressure makes the bags collapse
partially, causing the dust cake to crack and
fall into the hopper below.
 Fabric Collectors
• Reverse Jet
• In reverse-jet baghouses, individual bags are supported by a metal
cage, which is fastened onto a cell plate at the top of the baghouse.
• Dirty gas enters from the bottom of the baghouse and flows from
outside to inside the bags.
• The metal cage prevents collapse of the bag.
• Bags are cleaned by a short burst of compressed air injected through
a common manifold over a row of bags.
• The compressed air is accelerated by a venturi nozzle mounted at
the top of the bag.
• Since the duration of the compressed-air burst is short (0.1s), it acts
as a rapidly moving air bubble, traveling through the entire length of
the bag and causing the bag surfaces to flex.
• Flexing of the bags breaks the dust cake, and the dislodged dust falls
into a storage hopper below
 Fabric Collectors
• Reverse Jet
• Reverse-jet dust collectors can
be operated continuously and
cleaned without interruption of
flow because the burst of
compressed air is very small
compared with the total volume
of dusty air through the collector.
• Because of this continuous-
cleaning feature, reverse-jet dust
collectors are usually not
compartmentalized.
 Wet Scrubbers

• Dust collectors that use liquid are

commonly known as wet

scrubbers. In these systems, the

scrubbing liquid (usually water)

comes into contact with a gas

stream containing dust

particles. The greater the contact

of the gas and liquid streams, the

higher the dust removal efficiency

There is a large variety of wet scrubbers; however, all have of three basic

operations:

• Gas-Humidification - The gas-humidification process conditions fine

particles to increase their size so they can be collected more easily.

• Gas-Liquid Contact - This is one of the most important factors

affecting collection efficiency. The particle and droplet come into

contact by four primary mechanisms.

• Gas-Liquid Separation - Regardless of the contact mechanism used,

as much liquid and dust as possible must be removed. Once contact

is made, dust particulates and water droplets combine to form

agglomerates. As the agglomerates grow larger, they settle into a

collector.
• Gas-Liquid Contact - mechanisms
• Inertial Impaction - When water droplets placed in the path of a dust-
laden gas stream, the stream separates and flows around them. Due to
inertia, the larger dust particles will continue on in a straight path, hit the
droplets, and become encapsulated.
• Interception - Finer particles moving within a gas stream do not hit
droplets directly but brush against them and adhere to them.
• Diffusion - When liquid droplets are scattered among dust particles, the
particles are deposited on the droplet surfaces by Brownian movement,
or diffusion. This is the principal mechanism in the collection of sub-
micron dust particles.
• Condensation Nucleation - If a gas passing through a scrubber is
cooled below the dew point, condensation of moisture occurs on the
dust particles. This increase in particle size makes collection easier.
• The "cleaned" gases are normally passed through a mist eliminator
(demister pads) to remove water droplets from the gas stream.
• The dirty water from the scrubber system is either cleaned and
discharged or recycled to the scrubber.
• Dust is removed from the scrubber in a clarification unit or a drag chain
tank.
• In both systems solid material settles on the bottom of the tank.
• A drag chain system removes the sludge and deposits in into a
dumpster or stockpile.
• Wet scrubbers are categorized as follows:
• Low-energy scrubbers
• Low- to medium-energy scrubbers
• Medium- to high-energy scrubbers
• High-energy scrubbers
• Low-Energy scrubbers
• In the simple, gravity-spray-tower
scrubber, liquid droplets formed by
liquid atomized in spray nozzles fall
through rising exhaust gases. Dirty
water is drained at the bottom.
• These scrubbers operated at pressure
drops of 1 to 2 in. water gauge and are
approximately 70% efficient on 10 µm
particles.
• Their efficiency is poor-below 10
µm. However, they are capable of
treating relatively high dust
concentrations without becoming
plugged.
• Low- to Medium-Energy Scrubbers
• Wet cyclones use centrifugal force to
spin the dust particles (similar to a
cyclone), and throw the particulates
upon the collector's wetted walls.
• Water introduced from the top to wet
the cyclone walls carries these
particles away. The wetted walls also
prevent dust re-entrainment.
• Pressure drops for these collectors
range from 2 to 8 in. water, and the
collection efficiency is good for 5 mm
particles and above.
• Medium- to High – Energy Scrubbers
• Packed-bed scrubbers consist of beds of packing elements, such as coke,
broken rock, rings, saddles, or other manufactured elements.
• The packing breaks down the liquid flow into a high-surface-area film so
that the dusty gas streams passing through the bed achieve maximum
contact with the liquid film and become deposited on the surfaces of the
packing elements.
• These scrubbers have a good collection efficiency for respirable dust.
• Three types of packed-bed scrubbers are-
+ Cross-flow scrubbers
+Co-current flow scrubbers
+Counter-current flow scrubbers
• Efficiency can be greatly increased by minimizing target size, ie., using
0.003 in. diameter stainless steel wire and increasing gas velocity to more
than 1,800 ft/min
• High-Energy Scrubbers (ex. Venturi scrubbers)
• Venturi scrubbers consist of a venturi-shaped inlet and separator.
• The dust-laden gases enter through the venturi and are accelerated to
speeds between 12,000 and 36,000 ft/min.
• These high-gas velocities immediately atomize the coarse water spray,
which is injected radially into the venturi throat, into fine droplets.
• High energy and extreme turbulence promote collision between water
droplets and dust particulates in the the throat.
• High-Energy Scrubbers (ex. Venturi scrubbers)
• The agglomeration process between particle and droplet continues in the
diverging section of the venturi.
• The large agglomerates formed in the venturi are then removed by an
inertial separator.
• Venturi scrubbers acheive very high collection efficiencies for respirable
dust.
• Since efficiency of a venturi scrubber depends on pressure drop, some
manufacturers supply a variable-throat venturi to maintain pressure drop
with varying gas flows.
• Electrostatic Precipitators
• Electrostatic Precipitators use electrostatic forces to separate dust
particles from exhaust gases.
• A number of high-voltage, direct-current discharge electrodes are placed
between grounded collecting electrodes.
• The contaminated gases flow through the passage formed by the
discharge and collecting electrodes.
• The airborne particles receive a negative charge as they pass through the
ionized field between the electrodes.
• These charged particles are then attracted to a grounded or positively
charged electrode and adhere to it.
• Electrostatic Precipitators
• The collected material on the electrodes is
removed by rapping or vibrating the collecting
electrodes either continuously or at a
predetermined interval.
• Cleaning a precipitator can usually be done
without interrupting the airflow.
• The four main components of all electrostatic
precipitators are-
• Power supply unit, to provide high-
voltage, unidirectional current
• Ionizing section, to impart a charge to
particulates int he gas stream
• A means of removing the collected
particulates
• A housing to enclose the precipitator
zone
• The following factors affect the efficiency of electrostatic precipitators:
• Larger collection-surface areas and lower gas-flow rates increase
efficiency because of the increased time available for electrical activity to
treat the dust particles.
• An increase in the dust-particle migration velocity to the collecting
electrodes increases efficiency. The migration velocity can be increased
by -
- Decreasing the gas viscosity
- Increasing the gas temperature
- Increasing the voltage field
• There are two main types of precipitators:
• High-Voltage, Single-Stage - Single-stage precipitators combine an
ionization and a collection step. They are commonly referred to as
Cottrell precipitators.
• Low-Voltage, Two-Stage - precipitators use a similar principle;
however, the ionizing section is followed by collection plates (used
in Acs)
• The two major types of high-voltage precipitators currently used are-
• Plate
• Tubular
• Plate Precipitators –
• The majority of electrostatic
precipitators installed are the plate
type.
• Particles are collected on flat, parallel
surfaces that are 8 to 12 in. apart, with
a series of discharge electrodes
spaced along the centerline of two
adjacent plates.
• The contaminated gases pass through
the passage between the plates, and
the particles become charged and
adhere to the collection plates.
• Collected particles are usually removed
by rapping the plates and deposited in
bins or hoppers at the base of the
precipitator.
• Tubular Precipitators –
• Tubular precipitators consist of
cylindrical collection electrodes with
discharge electrodes located on the
axis of the cylinder.
• The contaminated gases flow around
the discharge electrode and up through
the inside of the cylinders.
• The charged particles are collected on
the grounded walls of the cylinder.
• The collected dust is removed from the
bottom of the cylinder.
• Tubular precipitators are often used for
mist or fog collection or for adhesive,
sticky, radioactive, or extremely toxic
materials.
• Particle Charging - Corona formation in ESP
• In an Electrostatic Precipitator, dust particles are charged by corona
current electrons flowing between the discharge electrodes and the
collection electrodes (or plates). The electrostatic field drives the
charged dust particles to the collecting plates.

electrode
corona
• Particle Charging - Corona formation in ESP
• This state is transient, once the excitation has ceased, the molecule
reverts to its ground state releasing energy
• Part of this energy gets converted light (bluish glow) – Corona
• The space between the wire and the plate can be divided into active zone
and the passive zone • In the active zone, defined by
corona glow discharge, electrons
leave the wire electrode
• In the passive zone, the electrons
impact gas molecules thereby
ionizing the molecules which
continues as chain of ionization
called Avalanche effect
• Particle Charging - Corona formation in ESP

• Typically, the discharge electrodes (wires) are energized while the

collecting plates are grounded, but the wires can establish either a

positive or negative corona.

• Negative corona (in which the wires have a negative charge) has

inherently better voltage/current characteristics, and is used more

frequently.

• However, negative corona produces more ozone than positive corona.

• For this reason, positive corona, even though less efficient, is used for all

indoor air cleaning applications.

• Particle Removal
• Dust that has accumulated to a certain thickness on the collection electrode
is removed by one of two processes, depending on the type of collection
electrode.
• Tubes are usually cleaned by water sprays, while plates can be cleaned
either by water sprays or a process called rapping.
• Rapping is a process whereby deposited, dry particles are dislodged from
the collection plates by sending mechanical impulses, or vibrations, to the
plates.
• Precipitator plates are rapped periodically while maintaining the continuous
flue-gas cleaning process.
• Plates are rapped when the accumulated dust layer is relatively thick (0.08
to 1.27 cm or 0.03 to 0.5 in.). This allows the dust layer to fall off the plates
as large aggregate sheets and helps eliminate dust re-entrainment.
• Dislodged dust falls from the plates into the hopper.
• Advantages of ESPs
• Very high efficiencies, even for very small particles
• Can handle very large gas volumes with low pressure drop
• Dry collection of valuable material, or wet collection of fumes and mists
• Can be designed for a wide range of gas temperatures
• Low operating costs, except at very high efficiencies

• Disadvantages of ESPs
• High capital costs
• Will not control gaseous emissions
• Not very flexible, once installed, to changes in operating conditions
• Take up a lot of space
• Might not work on particulates with very high electrical resistivity
• Gaseous Emission Control – Physical & Chemical Seperation
• Absorption – Absorption is a basic chemical engineering operation and
is probably the most well established gas control technique
• Used extensively in the separation of corrosive, hazardous or noxious
pollutants from waste gases
• Absorption involves transferring pollutants from a gas phase to a
contacting solvent
• To maximize the mass transfer driving force, the absorber generally
operates in a counter current fashion
• Absorption systems design involves selecting a solvent and the design
of the absorber
• Absorption
• Selection of the solvent
• Solubility is the most important consideration in the selection of a
solvent for absorption
• Higher the solubility, lower the amount of solvent required
• The solvent should also be non-volatile to prevent an excessive carry
over in the gas effluent
• Other properties of a good solvent are
• Low flammability and viscocity
• High chemical stability
• Acceptable corrosivity
• Low toxicity and pollution potential
• Absorption
• Absorber design
• Any gas-liquid contactors that promote the mass transfer across the
phase boundary can be used for absorption operation
• The most popular devices are spray towers, packed columns as well
as venturi scrubbers
• In case of packed columns, two types of packings are used
• Random packing
• Structured packing
• Either of the packing involve use of pall rings or intalox saddles
• Condensation
• In cases where pollutants have low vapour pressures, condensation is
effective for removing a significant part of the vapour
• The condenser works by cooling the feed gas to a temperature belw
the dew point of the feed gas
• Two types of condensers are normally used
• Surface condensers contact condensers

• Removal efficiencies of condensers typically range from 50

percent to more than 95 percent, depending on design and
applications.
• Adsorption
• Adsorption is the binding of molecules or particles to a surface.
• In this phenomenon molecules from a gas will be attached physically
to a surface.
• The binding to the surface is usually weak and reversible.
• The most common industrial adsorbents are activated carbon, silica
gel, and alumina, because they have enormous surface areas per unit
weight.
• In selecting the adsorbent, the adsorption isotherm of the adsorbent
should be favourable
• An adsorption isotherm for a single gaseous adsorptive on a solid is
the function which relates at constant temperature the amount of
substance adsorbed at equilibrium to the pressure (or concentration)
of the adsorptive in the gas phase.
• Other Methods
• Thermal destruction using thermal
combustion/incineration
• Biofiltration
• Biofiltration involves the removal of
oxidation of organic compounds from
contaminated air by beds of
compost, peat or soil.
• Biofiltration combines the
mechanism of adsorption, scrubbing
effect of water, and oxidation
• Soil and compost possess millions of
microbes which oxidize organic
compounds to carbondioxide and
water