Air pollution control

methods and equipments

Prevent the formation of pollutants or minimize their emission.

Source correction method:

Effluent gas cleaning techniques:

Efficient design and development of process

For existing plants its difficult to apply new designs
Raw material change, operational change, modification or replacement of process
equipment, effective operation of existing equip.
Involves many chemical engineering unit operations

Source correction methods

Raw material changes:

Use purer grade of Raw material.
ex: use of low sulphur fuel in place of high sulphur one
Burning of natural gas(limited availability) in place of coal
Coal gasification: easy to remove unwanted comp from gas
Gas can be produced by destructive distillationcoke is by-product
Gasification of coke residues of the carbonization process using steam,
CO2, O2 and Air. The main prod are H2, CO2, CO and undecomposed
steam.

Destructive distillation is the chemical process involving the decomposition of

feedstock by heating to a high temperature; the term generally applies to processing
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of organic material in the absence of air

Source correction methods

Process changes:
New or modified tech offer important ways of lowering atm pollutants emissions
Petroleum ind: volatile sub are recovered by condensation, non-condensable gases
are recycled for additional rxns.
EX: H2S recycled and used in claus process to recover the S
Rotary kilns: source for dust generation
dust control: adjusting the operating conditions, reduction gas velocities, modification
of rate and location of the feed introduction, use of dense curtain of light weight chain
at the discharge end.
Smelting and Paper ind: sulphurous material
Controlled by: major process changes- hydro metallurgical separations of ores, use of
no sulphides in paper making
Steel Ind: new process changes are proposed to lower sulphurous emissions during
combustion.
S contained fuel lime stone air molten iron bath
Combustibles partially oxidesed into CO and comes to top
S retained in molten iron bath and forms slog with limestone
Other Examples: Reduction of the formation of nitric oxides in combustion chambers
by low excess air combustion in two stages, flue gas recirculation and water injection
Washing of coal before pulverization to reduce the fly ash emissions
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Source correction methods

Equipment modification or replacement:

Unburnt CO and HC in the cylinder of an automobile engine can be burnt by injecting
the air into hot exhaust manifold of the engine.
In refineries: HC released into the atm from storage tanks due to temp changes,
evaporation, displacement during filling. Losses can be minimized by designing the
tank with floating roof covers or pressurising the tank.
Replacement of open hearth furnace by oxygen furnace in steel industry
Pollution emission can be reduced by: proper equip maintenance, housekeeping, and
cleanliness in the facilities and premises.
By Minimizing leakages.

Cleaning of gaseous effluents

Cleaning tech are required where emissions of pollutants can not be prevented.
Economical to install the control equip at source where the pollutants are present in the
smallest vol.
2 types: Particulate control type, gases and odours control type.
wet absorption, dry adsorption
Gases pollutants
Diffusion
chemical alteration of the pollutants
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Particulate emission control

Partly the diffusion and partly on nature and properties of the PM

Particles sizes range form 100m to 0.1 m.
Choice of collection devices: Physical and Chemical characterstics of particulates,
particle size and conc of gas, vol of particulates to be handled, and temp and
humidity of gaseous medium.

Collection efficiency

Particulate control equipment

Mechanism: Gravitational settling, centrifugal impaction, inertial impaction, direct

interception, diffusion and electro static precipitation
Equipments: gravitational settling chambers, fabric filters, electrostatic precipitators,
cyclone separators,
wet collectors (scrubbers).
Low efficiency for small size particles
high efficiency

Gravitational settling chambers:

Used for particles of size >50 m

Offer low pre drop, simple maintenance.
Generally used as pre cleaners
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Horizontal flow settling chamber

Howard settling chamber

Turbulent flow in settling chamber

Mass conc of particle

Mass conc of particle
entering the control vol - leaving the control vol =

Rate at which the

particles are deposited
with in the vol

To avoid short
circuiting

Reverse flow cyclone separator

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Because of a centrifugal force of mpv2 / r, the particle will

follow a path outward across the flow streamlines.
Its velocity vector will have a tangential component (v)
and a radial component (vr).

The velocity of the spinning gas is assumed to have only

a tangential component, u , with ur = 0.

Tangential gas flows of this type

u rn = constant.

For an ideal fluid flow in such a vortex flow n = 1, although

in real flows the value of n may range downward to 0.5.

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laminar Flow Cyclone Separators

flow cyclone does not have laminar flow in the

sense of the laminar flow settling chamber, but
rather a frictionless flow in which the streamlines
follow the contours of the cyclone.
u r =

p-f~p

v=u
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The distance traveled in the direction in a time

interval dt

The distance the particle moves in the r-direction

in time dt

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The differential equation describing the particle's

trajectory. If the particle enters the device at r =
r3 and hits the outer wall at = f

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collection efficiency of a cyclone

the cyclone has an angle fs =2Ne.

All particles that enter the cyclone at rr3 hit

the wall over 0 f

f fs

If the entering particle concentration all gas

velocity are uniform across the cross section,

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Particulate emission control

Filters

Packed filters

Packed filters: fibers are loosely packed inside an enclosure

Fabric filters: fibers are woven into a thin layer of fabric (natural, synthetic, metal or glass).
Particulate matter is trapped on to the fibers: Inertial impaction, direct interception and
diffusion.

Inertial impaction

Particles have high inertia

Collision factor c = 2y0 / df

Adherence factor a

Collection efficiency impact = c a

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Particulate emission control

Direct interception

Particles have less inertia and almost follow the stream line around the obstruction
If the particle centre is travelling on a streamline which is closer than the radius of
the particle, the particle will touch the fiber and deposited

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Particulate emission control

Packed filters:
Diffusion

Particles of submicron range (0.001-0.05 micro meter)

Estimate for combined efficiency of collection

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Particulate emission control

Fabric Filters

Open spaces in woven fabrics are usually many times the size of individual particles.
After short period of operation, the particles from a bridge across the cloth openings and
form a particle layer.
99% efficient
Cleaning and maintenance is required to prevent a deterioration of efficiency

Fabric and fiber characteristics

Woven fabrics:
Long range repeating pattern and have high porosity in the direction of gas flow
Open space must be bridged by impaction and interception
Felted fabrics:
Randomly oriented fibers compressed into a mat and needled to loosely woven backing
material.
Require less area for given loading
More expensive
Can not be used in high humidity service
Choice of fiber
Based on operating temp and corrosiveness
Ex: Cotton
Silicon coated glass fiber cloth
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Fabric Filter Systems

Consist of tubular bag
bag house

Orientation of bags
More number of bags

Cleaning: shaking the bags, increasing the air pre that deform sufficiently to dislodge the
accumulated dust.
Adv:
Very high efficiencies, retention of finest particle, collection of particles in dry form, low pre
drop
Disadv:
Large size, high construction cost, at low temp
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Electrostatic Precipitators

Used in power plants, cement and paper mills, oil refineries.

Particle suspended in gas stream are charged electrically, and separated under the influence
of the electrical field.

corona discharge occurs close

to the negative electrode.
Voltage 50kV

Wire and Pipe Precipitator

-ve ions and electrons charge the PM

Periodic cleaning is necessary.

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Electrostatic Precipitators

Parallel plate precipitator is frequently used in collecting liquid particles.

vertical plates exposed to horizontal gas flow.

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Collection Efficiency

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Wet Scrubbers

More efficient than dry collectors

Disad: Corrosion and liquid waste disposal
Basic principle is to provide contact between the scrubbing liquid and particulates

Adv: Particles & gases simultaneously removed

Wetted surface, individual droplets

Mechanisms: inertial impaction, interception >0.3m

and diffusion <0.3 m
Types of scrubbers:
.Spray towers, centrifugal scrubbers, packed beds and plate columns and venturi
scrubbers
Spray towers:
Particle collection results
because of inertial impaction
and interception on the
droplets.

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Wet Scrubbers

Centrifugal Scrubbers:
Collection efficiency is more than spray scrubbers
Simple centrifugal Scrubber: by inserting bank of nozzles inside a conventional
cyclone.
Spray acts on the particles in outer vertex.

Another Version
Gas is introduced tangentially at bottom
Water drops are injected into the flow
stream from sprays directed outward from a
center.
The droplets caught in the spinning gas
stream and thrown upward towards the wall
by centrifugal force.
During their motion the droplets collide with
the particle and capture them.

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Wet Scrubbers

Packed Beds and Plate Columns

The packing allows the gas stream
to take a curved path through the
pore spaces
Particle
captured
by
inertial
impaction
Bcz of high surface area of contact
its efficient for fine particles by
diffusion
Packing materials: Raschig rings,
Saddles, Coke or broken stone.
Plugging problems can be reduced
by using sprays to wash the packing
or using low density spheres.

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Impingement Baffle plate scrubber

Gas jet impinged the baffle

Particles are collected by
inertial impaction
Superficial gas velocity 5
times>the gas vel in
normal cols

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Venturi Scrubber

High efficiency for small particles(2 to 3 m)

Suitable for PM is sticky, flammable or highly corrosive
The particles are impacted against the slow moving
droplets.
Mechanisms: Inertial impaction, diffusion, condensation
and agglomeration

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Control of gaseous emissions

Sorption of pollutants, Chemical alteration of a pollutants

Absorption by Liquids

Concentration profiles

Selection of scrubbing medium:

High gas solubility, high selectivity, low vapor pre, non-corrosiveness, easy
regeneration, low costs, low viscosity, nontoxicity, nonflammability and chemical
stability.
Ex: SO2 NaOH; Nitrogen oxides ammonium bicarbonate, H2S NaOH, NH3
H2SO4

Gas absorption equipment: Packed towers, tray or plate towers, venturi scrubbers.

Venturi scrubbers: gas liquid flow in the same direction.

Liq is introduced at the throat of the venturi and dispersion of the liq is accomplished by
high vel gas stream.
Extremely efficient but high energy required

Basic Design Considerations:

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Adsorption by Solids

Adsorption is a surface phenomenon.

Attractive forces may be physical or chemical.
Physical adsorption: gases material condenses upon the surface of
the solid.
The adsorbed material can be removed by reducing the pre or by
increasing the temp.
Chemical adsorption: chemical interaction between the solid and
adsorbed material.
Heat of rxn is very high.
Uses: field of odour control
Collecting of valuable organic substances.
Rate of adsorption: conc of material around the adsorbent, surface
area of the adsorbent, pore vol of the adsorbent, chemical nature of
adsorbent surface, and temp.

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Adsorbents: activated carbon, activated alumina, silica gel.

Stages of adsorption:

Diffusion of pollutant from bulk gas phase to the external surface of the solid
Diffusion of gas molecule into pore of the solid
Adsorption on active sites in the pore (faster)

Mode of operation: batchwise or continuous

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Batch Adsorption

Based on material balance and equilibrium data

Equilibrium data q=f(c)

Material Balance
qfM + cfS = qM + cS

Plot q vs c

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Fixed Bed Adsorption

Gas pass through the packed bed at a const flow rate.
Mass transfer resistance, unsteady state process
The conc in fluid phase and solid phase change with time and with position as
adsorption proceeds

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Construction of Breakthrough curve

reffer to Treybal page no 634

Break through
Cb is the outlet conc
in the fluid

q0 saturated bed conc

Equilibrium time te : Time required to reach the rear end of the MT zone to top of
the bed
Effect of mass transfer on

shape curve
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Cb
C0 is feed conc
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Lb length of sat bed

0-a-a-d-g-c-b-0 used abs capacity
Adgfea unused abs capacity
Cde-> cdgc=adea
Amt of adsorbent required to fill the bed
length L-Ls remains effectively unused
LUB

Stoichiometric Front

About tb and te
ts is the stoichiometric time

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us velocity of Stoichiometric Front

L=usts
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Design calculations using LUB

Run the test column at desired gas flow rate.
Determine the value of LUB by finding tb and te from
the break through curve
Find u
s

LUB=L-Ls, usts-ustb

Compute the staichiometric height needed to produce

desired adsorption capacity. (Ls=ustb;)

i.e. decide how long you want to run the adsorption

process
Make the actual column longer by amount of the LUB,
to account unused adsorption capacity under actual
conditions.

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Combustion

Can be used when gas streams have no recovery values

If the waste gas contain sufficient combustible materials incineration
Combustion application destruction of odours, toxic sub, reactive
materials, prevention of explosion hazards, reduction of pollutants in
the oxidized form.
Products of combustion process odourless, colourless,
harmless(CO2, H2O).
High mol wt HC cause smoke prob.
inorganic material releases SO2 and oxides of N2.
Ensure complete combustion
For complete combustion time temperature and turbulence (3Ts).
Methods: Direct combustion, thermal incineration, catalytic oxidation.
flaring: highly combustible streams can be eliminated
Flaring is not efficient: gas stream contain high amt of inorganic
material- S, CL, F (Pretreat)

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Unsaturated HC with low H-C ratio produces smoke.

Steam injection through the jets

surrounding the flare tip
Adv: increase turbulence
Add heat to the combustion process
Sets up a water gas rxn (CO & H2)

Preheating is required if the inert

gases are present to ensure
minimum fume energy
concentration is not reached.

Steam Injection Type Flare

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Combustion

Thermal incineration:
For diluted gases pre heating is required.
waste gas is preheated over an auxiliary fuel fired burner
Temp 500 to 800
0.3 to 0.7 sec residence time to allow complete oxidation
Turbulence
Cost involved in the form of fuel required
Recovering the waste gas heat

Thermal Incinerator

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Regenerative Heat Recovery

Oxidiser followed by HTEX

Effectiveness of heat exchanger

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Combustion

Catalytic Oxidation
Useful when TI is not economical (fuel cost)
The combustion takes place on a catalyst usually at low temp (Comp with TI)
Temp necessary to initiate rxn depend upon the type of pollutant
Catalyst used are platinum and palladium or their alloys
Catalyst is coated onto sustainable ele metal ribbons, ceramic rods, alumina
pellets

1% excess O2 is used complete

combustion and maintain cat in active state
Recommended for PM and metallic sub
free gases (avoid poison)
Periodic cleaning is required

heated to req temp to

support the catalyst
combustion
Catalyst Combustion Unit
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