Air Pollution Control Systems

Serving Power and Industry

Introduction Dedusting systems are installed in various industrial and utility applications either to recover valuable quantities of process material or to achieve low ambient dust emissions. Heavy industry in general has made valuable contributions to ambient air quality in recent years, in part to comply with environmental protection directives, in part to satisfy the demands of local authorities and neighboring communities. Electrostatic Precipitators (ESPs), traditionally regarded as acceptable technology for reducing dust emissions from dust producing sources, are typically found on various processes such as cement and lime kilns, utility and recovery boilers, industrial and municipal waste incineration plants, as well as pulp and paper plants, among others. Still, many of these plants experience high dust emissions caused by transitory process conditions, mainly due to the precipitators inability to respond quickly to the changing conditions of the process. These emissions are easily avoided with the installation of add-on gas conditioning systems or by replacement with a properly designed modern fabric filter dedusting system. However, the importance of proven experience and process knowledge in the application of fabric filter dedusting plants or in devices to control the conditions at the inlet of an ESP cannot be underestimated. Choosing the right equipment type and design requires sophisticated methods of selection as well as provisions for efficiently operating those components, adapted to the prevailing construction, erection, operation, and environmental requirements. BoldEco possesses in-house know-how and experience in the selection, application and operation of most modern air pollution control equipment components and can be relied upon to choose the optimum solution from a variety of options. After many years of advising, developing and supplying such plants to various heavy MODERN CEMENT PLANT A modern cement plant is required to be environmentally friendly not only with respect to clean air and clean water it must be esthetically pleasing as well.

industries, including power, we have found the proper complement of operational experience, process knowledge and advanced analytical tools, resulting in truly advanced and efficient systems designs. BoldEco Solutions Since BoldEco possesses in-house experience to design, fabricate and erect complete gas moving and dust collection systems, we are in a unique position to provide completely integrated, single responsibility dedusting solutions. Due to our vast collective experience in the field of dedusting, our dust control technology is continually being updated to meet current and future requirements, and, by implementing newly developed technological improvements, achieves elevated efficiencies at a high level of reliability. BoldEco Environment has supplied both new and retrofit installations in response to the various regulations calling for increasingly efficient dedusting plants, always conscious of the customers need to cost-effectively achieve ever higher degrees of flexibility and reliability. Project Execution Projects can be carried out according to a clients wishes, based on the supply of system components only, on smart-parts and engineering for local fabrication and erection, or on complete turnkey projects, which may be more desirable due to sole-source responsibility. Since BoldEco manufactures and installs the main proprietary system components and large fabricated elements through cooperation with local partners, there is complete control over the entire project execution process. Projects are executed by competent project managers and engineers, who oversee the engineering, manufacturing and logistics. As much as possible, BoldEco ships pre-assembled components for ease of installation, as well as to maintain tight control over erection costs and installation schedules. Commissioning, acceptance testing and field service, completes our customer service regimen.

BoldEco Experience Together with our specialized partners and its competent affiliates around the world, we bring valuable experience to each application demanding a high degree of technical competence in design and engineering. It is just this specialized knowledge, vast experience and breadth of market coverage that allows us to compete at a very high level internationally . Already, a large number of systems are successfully operating in steel, power generation, cement, lime, incineration and other industries. BoldEco has proven that it can successfully execute large-scale, complex projects throughout the world and pledges to maintain its reliable partnership with industry and power by its continued investment in market expansion. Ancillary Equipment and Systems BoldEco is skilled in supplying more than just particulate filters. Our arsenal of technologies includes large process fans, general ventilation systems, air-to-air heat exchangers, evaporative gas cooling systems, SNCR DeNOx systems, materials handling and transport systems, DeSOx systems, both dry and semidry, including our patented LEC limestone emission control system, particulate and gas scrubbers, as well as other innovative gas cleaning technologies. Our equipment enjoys the enviable reputation of being a good value while providing all of the efficiency and reliability expected from a top quality air pollution control system supplier. Engineering and Customer Services BoldEcos in-house gas flow and sound measurement tools, as well as its numerical modeling software, such as Computational Fluid Dynamics (CFD), acoustics, pressure wave propagation, etc., allows us to provide timely expert field and engineering services to our customers at a reasonable price. As part of our customer service regimen, we have qualified service and technical personnel ready for a variety of field services or to provide an on-site technical evaluation of any new or existing pollution control application.

CEMENT and LIME KILNS

Rotary Kiln Applications Modern dry process cement kilns force hot kiln gases through a raw mill to dry the raw material, which is then recovered by a dedusting plant. For preventive maintenance purposes, a bypass is utilized to direct the gases around the mill, directly into the dedusting plant. In the case of a lime kiln or an older design cement kiln, the process may be different, but the gas cleaning plant has the same performance requirements. The dedusting plant has therefore to deal with 2 main gas conditions: 1) low temperature, high dust laden gases exiting the raw mill (combined operation); and 2) low dust load kiln exhaust gases, cooled by water injection in a conditioning tower or bleed in air (direct operation). The transition between these two operating conditions is especially difficult to handle with an ESP due to rapidly changing dust electrical characteristics. In those cases where the ESP performance needs to be improved, the installation of an efficient evaporative cooling system is recommended. The trend in recent years has been to replace or upgrade a process ESP with a process fabric filter. Various options in filtration fabrics are available today for installation in fabric filter plants. These modern fabrics have proven themselves capable of being exposed to varying moisture and temperature ranges as well as to varying concentrations of dust.

FABRIC FILTER with forced air cooler

CEMENT KILN FABRIC FILTER Gas flow: 540.000 m3/h - 317,647 Acfm Filtering surface: 10.000 m2 - 107,257 ft2

INCINERATION GAS CLEANING

Incinerator Applications Waste gases extracted from an incinerator must be treated with a gas cleaning system to remove the particulate by-products, as well as neutralize all of the acid gases and remove hazardous air pollutants. In many cases, a waste heat recovery boiler is installed after the incinerator (or secondary combustion chamber), where any precursors to Dioxins and Furans (D/F) combine due to optimum formation temperatures. A proven solution is the installation of an Evaporative Cooling Tower or a Lime Spray Dryer downstream of the boiler to rapidly lower the exhaust gas temperature and reduce D/F formation, as well as remove any acid gases, as in the case of a spray dryer. In the case of a cooling tower, Activated Carbon (A/C) is augmented by a Hydrated Lime injection system, installed upstream of a Fabric Filter in order to capture D/F, as well as any Heavy Metals (HM) present in the gases. The fabric filter can be fitted with special membrane filtration bags (and in some cases coated with catalysts or A/C) that correspond to the operating conditions and therefore guarantee durability of the bags and a clean gas content of less than 10 mg/Nm3. A wet gas scrubber often follows the particulate, D/F and Heavy Metals collection train to abate acid gases and to polish the exhaust gas stream to in order to meet local requirement.

INCINERATOR GAS CLEANING SYSTEM Including Fabric Filter, Dry Acid Gas Scrubbing Reactor and Reagent Recycle System

VIEW OF SPRAY COOLER Good gas distribution is a must in any GCT application

STEEL AND METALLURGICAL APPLICATIONS

Steel Mill Applications FOURTH HOLE Settling chamber on an Electric Arc Furnace Application Fabric filters can be designed to withstand high negative pressure, high temperatures and high dust loads, such as those found in the operation of steel mill furnaces. A special filter design is available that promotes uniform airflow distribution to ensure that the dust is well distributed on the collecting surfaces for properly balanced dust extraction and to maintain low pressure drops through the baghouse. Bags utilized in steel mill Electric Arc Furnace applications can be as long as 8 meters, employing traditional pulse jet technology. BoldEco have numerous installations where the successful implementation of a spray cooling tower has resulted in capital and operational savings to the customer.

SPRAY COOLER on an Electric Arc Furnace Application

FABRIC FILTER with axial cyclone

FILTERING GROUP with fan and stack

CANOPY DUCTS on an Electric Arc Furnace Application

COAL FIRING SYSTEMS

Coal Mill Applications Coal mill filters are installed in indirect firing applications (when the coal is milled and then fed to a burner in a separate step) in order to better control the combustion characteristics. In these cases, a coal collection filter must be installed, and it must be designed to ensure the prevention of coal dust accumulation and an airtight housing. The fabric filter housing is designed to withstand explosive pressures and must be equipped with a suitable number of rupture disk diaphragms or explosion doors. For a semi-direct firing system, our cyclones are installed in the milling circuit in order to separate the coal from the milling gases so that they can be fed to the burner with a separate fan, also furnished by BoldEco. Our designs incorporate all of the latest explosion suppression and protection techniques, including our surge suppressor modules.

COAL MILL FABRIC FILTER Gas flow: 40.000 m3/h - 23,530 Acfm Filtering surface: 670 m2 - 7,212 ft2 Showing surge suppressor module to vent explosions to atmosphere

CYCLONE FOR KILN FIRING Includes a surge suppressor module that vents the explosion to atmosphere to avoid damage to process equipment

EXPLOSION VENTS Installed on the baghouse inlet plenum according to specifications

HIGH PRESSURE BURNER FAN Gas flow: 40.000 m3/h - 23,530 Acfm

BOILER APPLICATIONS
Boiler Applications In most boiler applications, it is still acceptable to install electrostatic precipitators (ESPs) for the collection of flyash. ESPs tend to be more cost effective particulate control devices if the ash collected is low in resistivity, and if the resistivity remains constant throughout the operational parameters of a given installation. BoldEco Environment is capable of supplying the entire gas cleaning system for small boiler applications, including multicyclones, ESP and fan. Our technology allows us to offer two approaches to electrode cleaning, a European design implementing tumbling rappers and rigid frame discharge electrodes, as well as an American disign, implementing MIGI rappers and either weighted wire or rigid dischage electrodes.

WASTE HEAT BOILER ESP 2-field ESP on a waste heat boiler application

AVC LINEUP Automatic Voltage Controllers for dry ESPs

AVC CABINET Inside vew of a typical AVC controller cabinet

RAPPER CONTROL CABINET Wall mounted rapper control cabinet can be mounted locally to ESP rapper location

TRANSFORMER/ RECTIFIER SET Automatic Voltage Controller mouned directly onto T/R set

EVAPORATIVE COOLING SYSTEMS

Spray Cooling Tower Applications Cooling towers are used to cool and humidify hot gases in order to improve the efficiency of the dust collector or to allow the use of lower priced filter media. BoldEco implements low maintenance dual fluid air / water injection systems to drastically shorten the evaporation time, resulting in dry bottom operation. A sophisticated water regulation system coupled with rapid temperature sensors provides a quick response to temperature variations to achieve precise tower outlet gas temperatures. Detailed analyses, including model studies and computer simulations of gas distribution and tower geometries are carried out to prevent gas turbulence or poor gas / water interaction. SPRAY IN ACTION Dual-fluid atomization

HYDRAULIC SPRAY TOWER CONVERSION Dual-fluid atomization

SPRAY LANCE HEADERS Water and compressed air distribution to the lances

SPRAY SYSTEM VALVE RACK For precise temperature regulation

COOLING TOWER for cement preheater kiln

EQUIPMENT CONVERSIONS AND UPGRADES

When existing dedusting systems are no longer able to achieve the required exhaust gas emissions, either because of existing equipment design limitations or due to increased plant capacity, it is necessary to consider upgrading or completely replacing the existing dedusting plant. BoldEco has carried out several dedusting plant upgrades and has acquired extensive know-how in the study and execution of such projects. When considering such upgrades or conversions, not only must the ultimate plant efficiency be taken into account, but also the time required for conversion and integration with existing equipment due to short kiln shutdown requirements. Upgrade Design and Project Execution Baghouse Conversion Reverse gas or shaker to pulse jet Modifications to gas distribution Application of various filtering media ESP Conversion ESP to pulsejet fabric filter Conversion to hybrid design Conditioning Tower Conversion Redesign of inlet gas distribution section Replacement of water atomizing lances Replacement of regulation control system Exhaust Fan Conversion Impeller redesign for improved efficiency Impeller redesign for improved wear Impeller redesign for higher capacity

BEFORE AND AFTER ESP TO FABRIC FILTER CONVERSION A cement plant ESP converted to PulseJet Fabric Filter.

LIFTING NEW FABRIC FILTER Unit was pre-assembled on the ground and lifted as a unit. Changeover time, 1 week.

Filtering system conversion to fabric filter

ENGINEERING SERVICES
CFD Calculations BoldEco Environment has for acquired Computational Fluid Dynamics (CFD) technology, allowing for the simulatation and accurate study of fluid dynamics problems in various industrial applications Typical cases requiring the implemantation of CFD technology are the optimization of a poorly functioning GCT, a fabric filter exhibiting a high number of bag failures or in preperation of a system upgrade. The implementation of the results of this technology, if tempered by practical experience, can result in optimizing gas flow distribution, thus avoiding gas flow related problems like velocity differentials, recirculation, build-up and high wear. In heavilty custom-engineered applications with the presence of highly abrasive dusts, the verification of gas flow fields inside the dust collector itself allows the reduction or elimination of abrasion and wear on filter bags and other internal components. The optimization of the flow distribution is ESPs is indispensable to achieve the design efficiencies of the dust collector. By way of proper study of the fluid dynamics of an application, it is possible to obtain the information necessary to correctly engineer specific equipment.

CFD MODEL OF A SPRAY TOWER In-house capability

Typical CFD Applications Typical applications include: Pressure drop calculations Gas mixing verification Build-up and erosion control Settling chamber and separator efficiency CFD MODEL OF A FABRIC FILTER A study is carried out on each new project in order to ensure the proper performance characteristics CFD OF ESP TO BAGHOUSE CONVERSION Various runs using Computational Fluid Dynamics show how difficult it is to modify the gas flow in an ESP to PJFF conversion.

GAS AND PARTICULATE SCRUBBERS

EcoMist Technology

EcoMist Scrubber General Arrangement

BEFORE

AFTER

The top photo shows the emissions of a traditional high energy venturi scrubber. That same stack (photo below) displays no emissions after a EcoMist Scrubber upgrade.

Industrial emissions are generally composed of fine dry particulate and condensed aerosols resulting from cooling of the exhaust gas. These fine particles pose a challenge because they are difficult to capture, greatly affect stack opacity, and can contain significant concentrations of toxic compounds. The EcoMist technology is the result of the research into higher efficiency scrubbing with low energy requirements. It is specifically designed to collect sub micron particulate (<1.0 m), condensables, and gases at high efficiencies (>99.8%). More than a single technology, the EcoMist Scrubber is actually comprised of multiple novel gas cleaning devices, staged in series and in various combinations to achieve the required collection efficiency. The EcoMist Scrubber addresses the deficiencies of conventional scrubbers by dealing with their basic design flaws. The result is a proprietary technology that exhibits high collection efficiency on sub micron particulate and condensables, with high turndown capabilities and excellent energy recovery. Separate Scrubber Effluents The EcoMist Scrubber differs from conventional designs in that it segregates the various stage effluents. In a very practical way, the system is designed with separate drains for the quencher, the sub cooler and the collection stages, allowing for greatly reduced water treatment requirements, efficient re-use of effluents, selective alkali scrubbing, and reduced toxic effluent processing.

1
2

EcoMist Scrubber Typical Efficiencies

Particulate Condensables Heavy Metals Acid Gases

>99.8% 99% 95-99+% >99%

Stage 1 QUENCHING Gases are quenched to saturation with energy efficient atomizers. Eliminates 95 percent of particulate. Stage 2 SUBCOOLING/CONDENSING (Optional) Condenses to convert gaseous components into aerosols. Stage 3 ATOMIZATION Aerosols and particulate are induced into negative pressure flow field formed by the proprietary swirl nozzle. Stage 4 COLLECTION ELEMENT INLET Gas entrained aerosols and fines move faster than liquid scrubbing droplets, causing collision and particle capture. Stage 5 COLLECTION ELEMENT OUTLET After reaching equilibrium, scrubbing droplets shoot past aerosols and fines, causing further collisions and completing the collection process. Stage 6 SEPARATION High efficiency separator removes dirty droplets from the exhaust gases.

NUISANCE AND MECHANICAL COLLECTION

Nuisance Filtration In a modern plant, many individual small and medium sized filters are used for the dedusting of small production units, conveyor transfer points and other material handling or storage equipment. Our MBC Series fabric filters, solidly designed and dependable in service, are ready to satisfy all requirements with regard to reliability, low maintenance costs and spare part standardization. The available fans for these filters are built according to strict engineered standards and provide high performance in continuous service with low maintenance and dependability. Models are available with integral fans for ease of installation. Design Variations The MBC filters are available for different applications, with differing size bags, horizontal bag arrangements, oval bags, settling pre-chambers and for high pressure designs. Please request an MBC fabric filter technical brochure.

Multi-Cyclones Our multi-cyclone is designed for high temperature and abrasive dust applications. These multi-cyclones are used for high-efficiency separation of abrasive dusts from gases, and is especially suited for areas where pre-separation is desired or where plugging is a problem. The design and construction of the cyclones has been conceived for high temperature applications and fitted with hardened cast parts designed to withstand high abrasion.

CUSTOM PROCESS FANS

BoldEco supplies various large process exhaust gas fans. They are designed and manufactured according to the requirements for the various applications, for dirty as well as clean applications in power, cement, incineration, steel, etc. BoldEco can supply fans as large as 10,000 kW, and factory test fans as large as 1,000 kW.

KILN/MILL EXHAUST GAS FAN Gas flow: 828,000 m3/h - 487,000 Acfm Installed power: 3,000 kW

High wear fan impeller

ADVANCED AIR POLLUTION CONTROL SOLUTIONS Field and Engineering Services Materials Handling Systems Gas Cooling and Cleaning Systems Air and Gas Handling Systems Silencers and Acoustic Enclosures

Skillman, NJ 08558 www.boldeco.com