EPA-600/2-77-209b November 1977 Environmental Protection Technology Series AMERICAN AIR FILTER KINPACTOR 10x56VENTURI SCRUBBER EVALUATION Industrial Environmental Research Laboratory Office of Research and Development U.S. Environmental Protection Agency Research Triangle Park, North Carolina 27711 ------- RESEARCH REPORTING SERIES Research reports of the Office of Research and Development, U.S. Environmental Protection Agency, have been grouped into five series. These five broad categories were established to facilitate further development and application of environmental technology. Elimination of traditional grouping was consciously planned to foster technology transfer and a maximum interface in related fields. The five series are: 1. Environmental Health Effects Research 2. Environmental Protection Technology 3. Ecological Research 4. Environmental Monitoring 5. Socioeconomic Environmental Studies This report has been assigned to the ENVIRONMENTAL PROTECTION TECHNOLOGY series. This series describes research performed to develop and demonstrate instrumenta- tion, equipment, and methodology to repair or prevent environmental degradation from point and non-point sources of pollution. This work provides the new or improved technology required for the control and treatment of pollution sources to meet environmental quality standards. EPA REVIEW NOTICE This report has been reviewed by the U.S. Environmental Protection Agency, and approved for publication. Approval does not signify that the contents necessarily reflect the views and policy of the Agency, nor does mention of trade names or commercial products constitute endorsement or recommendation for use. This document is available to the public through the National Technical Information Service, Springfield, Virginia 22161. ------- EPA-600/2-77-2Q9b November 1977 AMERICAN AIR FILTER KINPACTOR 10 x 56 VENTURI SCRUBBER EVALUATION by Seymour Calvert, Harry Barbarika, and Gary M. Monahan Air Pollution Technology, Inc. 4901 Morena Boulevard, Suite 402 San Diego, California 92117 Contract No. 68-02-1869 ROAP No. 21ADM-029 Program Element No. 1AB012 EPA Project Officer: Dale L. Harmon Industrial Environmental Research Laboratory Office of Energy, Minerals, and Industry Research Triangle Park, N.C. 27711 Prepared for U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Research and Development Washington, D.C. 20460 ------- ABSTRACT An American Air Filter Kinpactor 10 x 56 venturi scrubber operating on the emissions from a large borax fusing furnace has been evaluated. The average total efficiency was 97.5 I during the test period. The venturi was operated at a pressure drop of 110 cm W.C., using about 33 liters/s of scrubbing liquor for a gas flow rate of approximately 20 Am3/s (43,000 CFM) at 80°C. The dust had a mass median aerodynamic diameter of about 0.8 ymA. The collection efficiencies of particles with aerodynamic diameters between 0.3 ymA and 3 ymA were determined from size distribution data taken with cascade impactors. The efficiency data showed the venturi to be more efficient than predicted for particle sizes below 1 ymA. Particle mass augmentation by con- densed water is a probable reason for the high efficiency for small particle collection. Diffusion battery data indicate the occurrence of some particle growth. Cost data supplied by the user showed that the venturi scrubber system initially cnst about $29,000/(m3/s) ($13.70/CFM) in 1970. This report was submitted in partial fulfillment of Contract No. 68-02-1869 by Air Pollution Technology, Inc. under the spon- sorship of the U.S. Environmental Protection Agency. 111 ------- CONTENTS Abstract iii Figures v Tables vii 1. Introduction 1 2. Summary and Conclusions 2 3. Source and Control System 3 4. Test Method 7 5. Process Conditions 10 6. Cascade Impactor Particle Data 13 7. Diffusion Battery Data 17 8. Particle Penetrations 19 9. Opacity 24 10. Economics 25 11. Operating Problems 26 12. Performance Comparison 27 Appendices A. Size Distribution Data 32 B. Venturi Scrubber Performance Model 43 IV ------- FIGURES Number Page 1 Schematic diagram of scrubbing system 4 2 Schematic top view of A.A.F. Kinpactor 10 x 56, shown in fully open position (dimensions in milli- meters') 5 3 Schematic of cyclone entrainment separator (dimen- sions in meters) 5 4 Modified EPA sampling train with in-stack cascade impactor 3 5 Particle penetration for run 2 20 6 Particle penetration for runs 4 and 5 20 7 Particle penetration for runs 6, 7 and 8 21 8 Particle penetration for runs 9, 10 and 11 21 9 Particle penetrations for runs 12 and 13 22 10 Pa^ ticle penetration for average of runs 12 and 13 compared to prediction \ 30 A-l Inlet and outlet size distribution for run #1 .... 36 A-2 Inlet and outlet size distribution for run #2 .... 35 A-3 Inlet and outlet size distribution for run #4 .... 37 A-4 Inlet and outlet size distribution for run #5 .... 37 A-5 Inlet and outlet size distribution for run #6 .... 38 A-6 Inlet and outlet size distribution for run #7 .... 33 A-7 Inlet and outlet size distribution for run #8 .... 39 A-8 Inlet and outlet size distribution for run #9 .... 39 ------- FIGURES (continued) Number A-9 Inlet and outlet size distribution for run #10. . , • 40 A-10 Inlet and outlet size distribution for run #11. . • • 40 A-ll Inlet and outlet size distribution for run #12. . . . A-12 Inlet and outlet size distribution for run #13. . . . 41 A-13 Size distributions from diffusion battery data. . . . 42 VI ------- TABLES Number Page 1 Inlet process conditions 11 2 Outlet process conditions 11 3 Outlet average gas composition 12 4 Particle size distribution summary 16 5 Mass loading and overall penetration 23 6 Opacity 24 A-l Inlet and outlet sample particle data for run #1 . . 33 A-2 Inlet and outlet sample particle data for run #2 . . 33 A-3 Inlet and outlet sample particle data for run #4 . . 33 A-4 Inlet and outlet sample particle data for run #5 . . 33 A-5 Inlet and outlet sample particle data for run #6 . . 34 A-6 Inlet and outlet sample particle data for run #7 . . 34 A-7 Inlet and outlet sample particle data for run #8 . . 34 A-8 Inlet and outlet sample particle data for run #9 . . 34 A-9 Inlet and outlet sample particle data for run #10 . . 35 A-10 Inlet and outlet sample particle data for run #11. . 35 A-ll Inlet and outlet sample particle data for run #12. . 35 A-12 Inlet and outlet sample particle data for run #13. . 35 VII ------- SECTION 1 INTRODUCTION Air Pollution Technology, Inc. (A.P.T.) conducted a perfor- mance evaluation of an American Air Filter Kinpactor 10 x 56 ven- turi scrubber in accordance with E.P.A. Contract No. 68-02-1869, "Fine Particle Scrubber Evaluations." The objective of the performance test was to determine fine particle collection efficiency as a function of particle size and scrubber parameters. Simultaneous inlet and outlet particle sampling measurements were taken on the scrubber during a six day test period during August, 1976. Cascade impactors, condensation nuclei counters, and a portable diffusion battery were used to obtain total mass loadings and size distribution data. The data and results of the evaluation of the scrubber are presented in the text. ------- SECTION 2 SUMMARY AND CONCLUSIONS The American Air Filter Kinpactor 10 x 56 venturi scrubber operating on the emissions from a large borax fusing furnace had an average total efficiency of 97.5 % during the testing period. The venturi was operated at a pressure drop of 110 cm W.C., using about 33 liters/s of scrubbing liquor for a gas flow rate of approximately 20 Am3/s (43,000 ACFM) at 80°C. The dust had a mass median aerodynamic diameter of about 0.8 ymA. The collection efficiencies of particles with aerodynamic diameters between 0.3 ymA and 3 ymA were determined from size distribution data taken with cascade impactors. The efficiency data showed the venturi to be more efficient than predicted for particle sizes below 1 ymA. Probable reasons for the higher ex- perimental efficiency in the smaller size range of particles were collection by condensation and particle growth. Diffusion battery data support the reasoning for the higher experimental efficiency for the smaller size range. The major condensation mechanism is that of water vapor on drops which have a low vapor pressure be- cause they contain dissolved borax (Na2Bi,07). Cost data supplied by the user showed that the venturi scrub- ber system initially cost about $29,000/(m3/s) in 1970. ------- SECTION 3 SOURCE AND CONTROL SYSTEM The emission source was a large borax fusing furnace used in continuous operation. The furnace was capable of producing 2.7 x 10s kg per day of anhydrous borax (NaalUOr) from the pentahydrated form of the feed, but was not always operating at full capacity during the testing. The particulates emitted were primarily the hydrated and anhydrous forms of borax which escaped during the drying and fusing processes. The total scrubbing system is shown in Figure 1, with the lo- cation of the sampling ports indicated. The gases from the fur- nace at a temperature of 1,000°C to 1,100°C are quenched by scrub- bing liquor to about 80°C. The gases then enter the American Air Filter Kinpactor 10 x 56 venturi scrubber, which is shown in sche- matic in Figure 2. The venturi is rectangular in cross section with a throat height of 142 cm (56 inches). The throat width is automatically controlled to maintain a pressure drop of about 110 cm W.C. (43 in W.C.) across the venturi. The throat width can vary from 0.64 cm (0.25 in) to 25.4 cm (10 in). Following the venturi the gases enter a cyclone entrainment separator which is shown in Figure 3. The gas is moved through the scrubbing system by a blower which is rated at 44 Am3/s at 84°C and 114 cm W.C. pressure differential (93,500 ACFM, 184°F, 45 in W.C.). The blower is powered by a 746 kW (1,000 HP) motor. The gases exhaust to the atmosphere through a 21 m tall, 2.13 m diameter stack. The scrubbing liquor is recycled through a tank which is fed about 28 H/s of fresh liquor or lesser amounts of fresh wa- ter. About 22 £/s of concentrated liquor is pumped from the bot- tom of the tank so that the borax concentration of the liquor is maintained at from 10 to 15 percent. ------- To Atmosphe From i ,nnn°r j T • .1 1 _ , Sampling Liquor -~*"| j Quencher Port f1 */f Cyclone i—i \ Sampling } Port Venturi j 20 m3/s V ^Z^\~"" 1 1 ~f 1 1 | f ^V I 1 J y c j [ lo Liquor To r " I 111™ Recycle 41 l/s Recycle Tank rmax.) Tank Blower rel ^Ba^BMMMHH Stack 70°C 25 m?/s Figure 1. Schematic diagram of scrubbing system. ------- Flow Direction 510 254 (max) 710 1830 Figure 2. Schematic top view of A.A.F. Kinpactor 10 x 56, shown in fully open position (dimensions in millimeters). ------- 2.13 Figure 3. Schematic of cyclone entrainment separator (dimensions in meters) ------- SECTION 4 TEST METHOD The performance characteristics of the American Air Filter Kinpactor 10 x 56 venturi scrubber were determined by measuring the particle size distribution and mass loading of the inlet and outlet gas simultaneously. For the tests performed in August 1976, modified E.P.A. type sampling trains with in-stack heated University of Washington Mark III (U.W.) cascade impactors were used for particle measure- ments above 0.3 ymA. Figure 4 shows a schematic diagram of the modified sample train. Glass fiber filter (Gelman type AE) sub- strates were used in the impactors to prevent particle bounce and , minimize wall losses. Low velocity impactor jet stages were used for the majority of test runs on the inlet sampling to increase the sampling time. The Air Pollution Technology portable screen diffusion bat- tery (A.P .T. -S.D.B .) was used for particle measurements from 0.1 ym to 0.01 ym (actual). The A.P.T.-S.D.B. uses Brownian diffusion to accomplish the size fractionation of particles smaller than 0.1 ym. Because smaller particles diffuse more readily than larger ones, succes- sively larger particles are captured as they proceed through the battery. A condensation .nuclei counter (C.N.C.) was used to determine the particle number concentration at several locations in the battery. From this data, the size distribution may be determined for the particles smaller than 0.1 ym. The size distribution computation was based on a calibration of the S.D.B. performed in the A.P.T. laboratory. During an impactor run, inlet or outlet fine particle size measurements were taken with the portable diffusion battery. ------- oo PRECUTTER AND NOZZLE 1 THERMOMETER mpINGER TRAIN HEATED CASCADE IMPACTOR ORIFICE METER 7 'l I r L STACK ' WALL 'h fl •2. { MANOMETER | THERMOMETERS _T|ROTAMETER VACUUM GAUGE DRY GAS METER VACUUM PUMP SILICA GEL DRYER Figure 4. Modified EPA sampling train with in-stack cascade impactor ------- Since the system remained fairly constant during the test period, inlet and outlet S.D.B. measurements at different times were con- sidered to approximate simultaneous sampling. Impactor blank runs on the inlet were performed periodically to insure that the substrates did not react with the stack gases. A blank impactor run consisted of an impactor preceded by two glass fiber filters run at identical sample conditions as the actual sampling runs. Gas flow rates for all tests were determined by means of a calibrated standard-type pitot tube along with in-stack taps for continuous wet and dry bulb temperature measurements. Velocity traverses of the inlet and outlet were performed according to the E.P.A. standards and average velocity points selected for one- point sampling. Sampling flow rates were measured with the usual E.P.A. train instruments so as to obtain isokinetic sampling. Orsat analysis of the outlet gases was also performed. The inlet sample ports were located in the best place avail- able, but in a relatively poor location for sampling. The inlet duct was square and 1.52 m (5 ft) on a side. The sample ports were 0.4 duct diameters downstream of a 90° bend and 1 duct dia- meter from the beginning of the venturi section. Twenty point velocity traverses through the center of the duct from both the top and the side were used to determine the flow rate and the lo- cation for the cascade impactor sampling. Since the flow was not well developed at the inlet sampling port, the inlet flow rate values are less reliable than the outlet flow rates. The outlet sample ports were located in a 2.13 m (7 ft) dia- meter round stack, five diameters downstream of the inlet from the fan and about 4 diameters upstream of the stack exit. The velo- city traverses indicated well developed flow. ------- SECTION 5 PROCESS CONDITIONS Thirteen cascade impactor sampling runs were made over a period of six days. The gas conditions at the inlet and outlet sampling locations during the runs are shown in Tables 1 and 2. It is thought, from observations of the amount and consistency of the product from the fusing furnace during the period, that the conditions during runs 9 through 13 are most representative of normal conditions. The average barometric pressure during the testing period was 93.63 kN/m2 (27.65 in Hg) . Close examination of the inlet and outlet flow rates un- covers a violation of the mass conservation law since the outlet flow rate is greater than the inlet flow rate while the inlet temperature is greater than the outlet temperature. The static pressures are practically equal. There are two explanations for this flow rate discrepancy: 1) As noted previously, the inlet flow is not well developed and thus the inlet flow rate is probably not accurate and, 2) air could be leaking into the system because of the low pressure (-110 cm W.C. gage) within the system between the venturi and the blower. The results on the Orsat analysis of the outlet gas are pre- sented in Table 3. 10 ------- TABLE 1. INLET PROCESS CONDITIONS Run 1 2 3,4,5 6,7,8 9,10,11 12,13 Temp. °C 75 108 73 78 79 81 Water Volume Percent * 36 57 14 23 49 41 Static Press. cm W.C. -8.3 -6.5 -6.1 -7.2 -7.5 -8.6 Flow Rate Am3/s (ACFM) 24 (51,000) 21 (45,000) 16 (35,000) 18 (38,000) 20 (42,000) 20 (43,000) TABLE 2. OUTLET PROCESS CONDITIONS Run 1 2 3,4,5 6,7,8 9 , 10, 11 12,13 Temp. °C 80 73 72 68 71 69 Water Volume Percent * 31 33 38 28 23 21 Static Press. cm W.C. -0.5 -0.4 -0.4 -0.4 -0.4 -0.4 Flow Rate Am3/s (ACFM) 29 (62,500) 25 (54,000) 25 (54,000) 25 (54,000) 25 (53,000) 25 (53,000) * Based on wet and dry bulb temperatures 11 ------- TABLE 3. OUTLET AVERAGE GAS COMPOSITION Gas Component N2 02 C02 CO H20 Molecular Wt . Volume Percent Wet 60 6 5 0 29 26 Volume Percent Dry 85 8 7 0 29 12 ------- SECTION 6 CASCADE IMPACTOR PARTICLE DATA Particle size distribution data were obtained for the Ameri- can Air Filter Kinpactor venturi scrubber as described in the Test Method section. Identical single point sampling at the average velocity location was performed at both the inlet and outlet. The sampling time of each run depended on the mass loading. The aver- age sampling times for the inlet and outlet were nine and fifty minutes respectively. Because of the number of very large particles in the inlet gas and the entrained water droplets at the inlet and outlet, pre- cutters were used. The aerodynamic cut diameters of the inlet and outlet precutters were approximately 12 ymA and 4.5 ymA re- spectively. The inlet sampling was approximately isokinetic. However, because of the large amount of water droplets in the outlet gas, a special "rain can" had to be used on the outlet sampling nozzle. Also, the outlet sampling nozzle was oriented perpendicular to the gas flow. The velocity through the outlet nozzle was maintained at the velocity of the outlet flow at that location. Isokinetic conditions are not crucial for sampling fine particles. For example, the error caused by sampling 4 ymA par- ticles at a velocity 501 higher or lower than the gas stream ve- locity would only be 2 or 3% of the concentration. The use of single point sampling and perpendicularly oriented nozzles is usually permissible when measuring fine particle size and concentration. The fine particles will be distributed well in the gas stream, except in cases where streams with different particle concentrations have not had sufficient time to mix. To illustrate that one-point sampling is sufficient for fine parti- 13 ------- cles, we may note that Stokes stopping distance of a 3 umA par- ticle with an initial velocity of 15 m/sec (50 ft/sec) is about 0.04 cm (0.016 inches) and for a 1 ymA diameter particle is one- ninth of that. Since the stopping distance is the maximum that a particle can be displaced from a gas streamline by going around a right angle bend, it is apparent that fine particle distribu- tion in the gas stream will be negligibly affected by flow direc- tion changes. To minimize the possibility of condensation in the impactors and to collect only the dry particles, the impactors were main- tained at about 15°C above the gas stream temperature by heating blankets. The precutters were not heated. The fact that the impactors were heated should be noted when interpreting the size distribution data. Some unpublished data taken with heated and unheated cascade impactors in a stream of wet borax particles have shown differences in the size distribu- tions. The primary difference was that the mass median aerody- namic diameter of the borax particles collected in heated impac- tors was as low as 70 percent of the mass median aerodynamic diameter of the particles collected in unheated impactors. Thus, the venturi scrubber of the present system, which operates on the principle of impaction, may be experiencing larger aerodynamic size particles than the heated cascade impactor data indicate. Data from run 3 are not included because the outlet cascade impactor stages had become wet. This happened because sampling with a parallel orientation of the outlet nozzle was tried for this run. Particle concentration, particle size and sampled volumes for cascade impactor runs are tabulated in the Appendix in Tables A-l through A-12. Size distributions for the impactor runs are given in Figures A-l through A-12 located in the Appendix. The inlet and outlet size distributions both indicate a bimodal na- ture. The straight dashed lines drawn on Figures A-l through A-12 represent the region of the size distributions where 14 ------- log-normality may exist. The lines on the outlet distributions may approximate the lower range mode of a bimodal log-normal distribution. For want of a better ananlytic description of the size distributions, the mass mean geometric diameters and geomet- ric standard deviations for the log-normal parameters as well as the mass median diameter (from the data points) runs are presen- ted in Table 4. In this report, the symbol "d " refers to aerodynamic dia- meter, which is equal to the particle diameter (d ) in microns (ym) times the square root of the particle density (p ) in grams per cubic centimeter (g/cm3) times the square root of the Cunning- ham slip correction factor (C'J. The symbol "ymA" represents the units of aerodynamic size. 15 ------- TABLE 4. PARTICLE SIZE DISTRIBUTION SUMMARY Run 1 2 4 5 6 7 8 9 10 11 12 13 Inlet pm ymA 0.80 0.94 0.86 0.92 0.82 0.66 0.86 0.76 0.94 0.75 d PS ymA 0.84 0.99 2.3 0.77 1.9 0.85 0.79 0.55 0.83 0.69 1.2 0.72 'g 2.1 3.3 3.7 2.7 3.3 4.7 3.3 2.7 3.3 2.7 3.3 3.0 Outlet pm ymA 0.40 1.1 0.32 0.33 0.23 0.25 %. ymA 0.55 0.78 0.32 0.22 0.41 0.20 0.22 0.13 0.16 0.25 0.16 0.19 a g 2.0 3.2 2.6 2.9 2.1 2.8 3.4 3.6 3.5 5.2 3.6 3.5 Note: pm Pg g mass median aerodynamic particle diameter from data log-normal geometric mass mean aerodynamic particle diameter log-normal geometric standard deviation 16 ------- SECTION 7 DIFFUSION BATTERY DATA Diffusion battery data were taken during the fifth and sixth days of testing. The inlet data were taken during cascade impac- tor runs 9, 10 and 11, while the outlet data were taken during runs 12 and 13. The average diffusion battery data particle size distribution for the inlet and outlet are shown in Figure A-13 in the Appendix. Because of the large amount of water vapor (40% by volume) in the gas, the lenses in the condensation nuclei counter of the diffusion battery would fog when the diffusion battery was opera- ted in the normal manner. Increased dilution did not solve the problem because the particle count would then drop below the threshold of the counter. Also, heating the diffusion battery to its maximum allowable temperature in an effort to reduce conden- sation on the lenses did not help. The modification to the system that allowed data to be taken was to route the incoming source gas through a glass flask before entering the diffusion battery. Enough of the water vapor con- densed in the flask so that the condensation nuclei counter did not become inoperable. Any condensation of water vapor would cause collection of submicron particles by diffusiophoresis. Thus, a fraction of the particles did not reach the diffusion battery. Since the diffusion battery data were taken with condensa- tion occurring within the system, the size distributions shown in Figure A-13 of the Appendix may not be accurate. However, since the configurations for taking the outlet data and the inlet data were the same and the process was constant during the testing period, the data may indicate something about the relation between the distribution of submicron particles of the inlet and outlet. The data do show that the outlet submicron particles are larger 17 ------- and more monodisperse. The data showing particle growth are only qualitative since condensation occurred within the measuring system. Mechanisms for particle growth are present in the scrubber system. These mechanisms are discussed in the section on performance compari- sons . 18 ------- SECTION 8 PARTICLE PENETRATIONS Particle penetration versus particle aerodynamic diameter was calculated from the cascade impactor data. The results are shown in Figures 5 through 9 for each day of testing. Penetra- tions for run 1 are not shown because they are much higher than the penetrations for all the other runs, indicating anomalous behavior. Penetrations for runs of the last two days, when opera- tions were smoothest, are quite consistent. Because the size distributions were not log-normal all of the penetrations were calculated manually. The manual method in- volved visually determining the slope of the cumulative mass load- ing versus aerodynamic particle diameter curve, drawn from the data presented in the Appendix. The ratio of the slopes of the outlet curve to the inlet curve at a certain particle size was the penetration for that particle size. Particle penetration based on diffusion battery data is not presented because of the inaccuracies incurred during the data acquisition. Diffusion battery data are discussed in the previous section. The total mass loadings and overall penetrations for the runs are presented in Table 5. The total mass loading was deter- mined from analysis of the cascade impactor data. Run 1 had ano- malously high overall penetration and high flow rates which indi- cated that something may have been wrong with the data or that the venturi was not operating properly during that run. The average penetration for all of the runs, exclusive of run 1, was 2.51. As noted previously, the size distributions were obtained from analysis of heated cascade impactor data. The effect of this heating was discussed in the section on cascade impactor data. 19 ------- 0.1 ts) o 0.04 § p-l o 0.01 ft. 0.004 0.001 0.3 0.5 PARTICLE AERODYNAMIC DIAMETER, dpa, ymA I Figure 5. Particle penetration for run 2. 0.001 0.3 0.5 PARTICLE AERODYNAMIC DIAMETER, d a, ymA pa Figure 6. Particle penetration for runs 4 and 5. ------- 0.04 2 O i—i H U o I-H H W 2 o.oi ;; o.oo o.i 0.004 0.5 PARTICLE AERODYNAMIC DIAMETER, d , jimA pa Figure 7. Particle penetration for runs 6, 7, and 8. 0.04 O H i PL, o 0.01 H W W 0.004 0.001 0.3 0.5 1 23 PARTICLE AERODYNAMIC DIAMETER, d^-umA pa Figure 8. Particle penetration for runs 9, 10 and 11. ------- 0.001 imilMIIIIIIIIIII IIIMIIIMMIIIIIIIIIIII 0.3 0.5 PARTICLE AERODYNAMIC DIAMETER, d , umA pa Figure 9. Particle penetrations for runs 12 and 13. 22 ------- TABLE 5. MASS LOADING AND OVERALL PENETRATION Run 1 2 4 5 6 7 8 9 10 11 12 13 Inlet Mass Loading mg/DNm3 332 653 1,150 841 690 2,310 882 829 1,040 863 1,210 1,000 Outlet Mass Loading mg/DNm3 40.4 18.3 42.1 11.0 21.9 18.4 20.5 22.7 19.3 31.0 36.9 27.3 Penetration % 12.2 2.8 3.7 1.3 3.2 0.8 2.3 2.7 1.9 3.6 3.0 2.7 23 ------- SECTION 9 OPACITY Opacity for the outlet stack of the American Air Filter Kinpactor 10 x 56 venturi scrubber was determined by personnel trained and certified by the California Air Resources Board. t Readings were made hourly during the testing periods. The opa- city determinations were made somewhat difficult by the presence of steam condensation in the plume and the proximity of other stacks emitting similar particulates. Table 6 presents the daily average opacity readings. Date 8/19/76 8/20/76 8/21/76 8/22/76 8/23/76 TABLE 6. OPACITY Runs_ Average Opacity, % 2 10-15 3-5 15 6-8 20 9-11 15-20 12,13 20 Average Outlet Loading, 9 12 11 14 19 24 ------- SBCTION 10 ECONOMICS Data for the initial costs of the venturi-cyclone scrubbing system, purchased in 1970, were supplied by the user: Approximate scrubber purchase cost $200,000 Scrubber auxiliaries: 1, Fans, motors, etc. 30,000 2. Ducting 47,000 3. Liquid and solid handling and treatment 50,000 4. Instrumentation 45,000 5. Electrical material 36,000 Scrubber installation: 1. Site preparation 108,000 2. Installation 100,000 3. Start-up and modification 51,000 4. Engineering 63,000 Total Initial Cost - $730,000 The operating costs were not available. However, the power costs can be estimated. The major power user is the large blower, The blower is powered by a 746 kW (1,000 HP) motor. At $0.03 per kW-hour the fan would cost $22 per hour, or $537 per day. 25 ------- SECTION 11 OPERATING PROBLEMS The primary operating problems with the system are the plug- ging of nozzles and piping and scale build-up in the system. These problems are all caused by calcium carbonate and sulfate deposits. The local water is very hard and the feed to the fusing furnaces may also contain these mineral impurities. To combat this prob- lem special reamer nozzles have to be used and the system has to be shut down periodically to chip away the built-up scale. Although a large amount of entrained water was carried-over from the entrainment separator through the fan, and out the stack, it was not considered a problem by operating personnel. 26 ------- SECTION 12 PERFORMANCE COMPARISON The performance of venturi-type scrubbers has been modeled extensively. The most recent survey and model* are presented in the Appendix and used here. The scrubber parameters are known or estimated as follows: Pressure drop 110 cm W.C. Gas flow rate 20 Am3/s Liquid flow rate 0.033 m3/s (QL/QG=0.00171 Maximum throat area 0.361 m2 Minimum throat velocity 69 m/s Gas temperature 75°C Gas density 0.79 kg/m3 Gas viscosity 1.6 x 10" kg/m-s Liquid density 1,000 kg/m3 The gas flow rate chosen was based on outlet flow rate for runs 12 and 13 and the liquid flow rate was taken at 80 percent of the stated flow rate since it is believed that because of plug- ging the maximum rate was not maintained. From the known pressure drop and a value of 0.8 for the re- covery factor in the pressure equation, the following are derived: Throat gas velocity 89 m/s Throat area 0.28 m2 Liquid drop diameter 0.0104 cm Using the equations presented in Appendix B a predicted penetration versus particle aerodynamic diameter curve was con- *Calvert, S., S. Yung and H.F. Barbarika, "Venturi Scrubber Per- formance Model," A.P.T., Inc., San Diego, CA, EPA Contract #68-02- 1328, Task No. 13, July 1976. 27 ------- structed. This curve is the "prediction" curve on Figure 10. In order to compare the model with experiment a few important factors need to be noted: 1. Heated impactors - As explained previously the inlet and outlet size distributions were determined using heated cascade impactors. Based on previous experience it was expected that the mass median diameters of the actual wet borax particle size distributions were up to 1.5 times the sizes measured in the heated impactors. The high solubility of borax was the primary reason for the difference. Thus the venturi was collecting lar- ger particles than those measured in the heated impactor. In order to compare the experimental results with the prediction it is necessary to plot experimental penetration against the actual (wet) particle size rather than the dried particle size. This correction causes the measured penetration curve in Figure 10 to shift toward larger particle diameters. 2. System leaks - The actual scrubber penetrations could also be different from those based on the impactor data because of dilution of the outlet by air leaks into the system, which probably did occur. Dilution of the outlet stream would cause the actual penetrations to be greater than those measured by a factor equal to the dilution factor. The outlet concentration may have been diluted as much as 25%. The dashed line on Figure 10 includes the effects of 25% dilution and 1.5 times particle growth on measured data. 3. Collection mechanism - The model for ventrui performance assumes particle collection by inertial impaction on drops in the throat region of the venturi. This model does not account for forces other than inertia which can effect submicron parti- cle collection. Thus, in the region below about 0.5 ymA the predicted penetration and the experimental penetration are expec- ted to differ. Another important phenomenon is the collection of particles of all sizes due to solution induced condensation. Borax (NaaB is highly soluble in water. If the scrubber liquor became more concentrated than would be in equilibrium with the vapor, it is 28 ------- conceivable that particles could be swept toward the liquid as water vapor moves to condense on it. The liquid drops which con- tain dissolved borax have a reduced vapor pressure which in- duces the condensation which causes the growth in particle size manifested in the differences between wet and dry particle sizes . Some of this dissolution and condensation will have occurred in the quench section upstream of the venturi. However, because of the large amount of liquid injected at the venturi these mechanisms may still be causing particle collection and growth downstream of the venturi. Growth or collection of the submicron particles after the inlet sampling point, either before or after the venturi would explain some of the differences between the predicted and the experimental penetrations. Condensation can also occur when the vapor pressure of the water is reduced because it is at a lower temperature than the adiabatic saturation temperature of the gas. This cause of con- densation was not significant here because there was very little cooling of the scrubber liquor. 4. Sensitivity of prediction to L/G ratio - The predicted curve is very sensitive to the liquid to gas volume flow rate ratio (L/G) for particle diameters above 1.0 ymA. A 25% decrease in the L/G ratio would cause the prediction to agree closely with the data. Since neither the inlet gas flow rate nor the liquid flow rate are known precisely, it is possible that the actual L/G ratio was lower than the value used in the prediction. 5. Entrainment - The carry-over from the cyclone was so heavy that precutters had to be used on the outlet sampling probe. It was possible that some smaller entrainment drops, containing dissolved borax, penetrated the precutters or were shattered in the precutters and were collected in the heated impactors. Since the venturi model assumed that no entrainment carry-over occur- red, the actual penetrations would be greater than the model prediction, as seen in Figure 10. These five factors help explain the differences between the 29 ------- 0.10 0.04 H U o 0.01 i—i H 0.004 0.001 Prediction Corrected for Wet Particles With Dilution Measured for Dry Particles 0.3 0.5 PARTICLE AERODYNAMIC DIAMETER, d , ymA pa Figure 10. Particle penetration for average of runs 12 and 13 compared to prediction. 30 ------- model prediction and the data. The many factors and uncer- tainties involved are enough to preclude any judgment of the accuracy of the model. 31 ------- APPENDIX A SIZE DISTRIBUTION DATA 32 ------- TABLE .VI. INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN * 1 IMP ACTOR STAGE NUMBER Precutter 1 2 3 4 5 6 7 Filter Sample Volume CDNm3) INLET M cum (mg/DNm3) 332 312 273 273 263 228 74.4 39.7 39.7 d Pc CumA) * 35.8 3.06 1.75 0.97 '0.58 0.32 0.19 0.020 OUTLET M cum Cmg/DNm3) 40.4 37.3 36.6 35.9 34.7 33.7 31.8 23.9 4.45 d Pc OmA) * 16.1 7.06 2.73 1.38 0.79 0.44 0.25 0.584 TABLE A-2. INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN *2 IMPACTOR STAGE NUMBER Precutter 1 2 3 4 5 6 7 Filter Sample Volume CDNm3) INLET Mcum Cmg/DNm3) 653 458 458 447 422 284 165 85.2 45.4 V CumA) 30.0 2.57 1.47 0.81 0.49 0.27 0.16 0.053 OUTLET Mcum Cmg/DNm3) IS. 5 14.3 11.6 10.7 10.4 9.56 8.42 6.99 3.00 V CvmA) 16.7 7.31 2.83 1.43 0.82 0.45 0.26 0.701 The inlet and outlet d 's for the precutters averaged approximately 12 ymA and 4.5 umA respectively for all runs. TABLE A-3. INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN #4 IMPACTOR STAGE NUMBER Precutter 1 2 3 4 5 d 7 Filter Sample Volume (DNm3) INLET "CUK (mg/DNm3) 1500 524 51? 498 461 360 218 113 46.1 d pc (pmA) 44.3 3.79 2.17 1.20 0.72 0.40 0.23 0.024 OUTLET Mcum Cmg/DNm3) 42.1 38.3 32.7 31.9 31.7 30.3 29.6 27.5 18.2 V CumA) 17.2 7.51 2.91 1.47 0.84 0.46 0.27 0.788 TABLE A-4. INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN #5 TMPAfTOR STAGE NUMBER Precutter 1 2 3 4 5 6 7 Filter Sample Volume CDNm3) INLET Mcum Cmg/DNm3) 841 - 714 714 708 692 602 320 181 107 d pc CvmA) 41.6 3.56 2.04 1.12 0.68 0.37 0.22 0.019 OUTLET . Mcum Cmg/DNm3) 11.0 10.0 10.0 10.0 10.0 10.0 9.63 8.23 5.83 V CumA) 16.1 7.04 2.72 1.37 0.79 0.43 0.25 0.789 ------- TABLE A-S. INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN 06 IMP ACTOR STAGE NUMBER Precutter 1 2 3 4 5 6 7 Filter Sample Volume (DNm3) INLET M_ ,m cum (mg/DNm3) 691 417 293 293 283 233 159 34.8 24.8 d pc CvmA) 38.8 3.32 1.90 1.05 0-.63 0.35 0.20 0.020 OUTLET M cum Cmg/DNm3) 21.9 20.0 18.9 18.2 17.4 16.7 15.3 13.3 4.58 d V CumA) 14.7 6.42 2.48 1.25 0.72 0.40 0.23 0.873 TABLE A-6. INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN #7 TMPAfTOR STAGE NUMBER Precutter 1 2 3 4 7 Filter Sample Volume (DNm5) INLET Mcum (mg/DNm3) 2310 2040 1910 1820 1720 1420 811 678 506 d PC CvmA) 40.8 3.49 2.00 1.10 0.67 0.37 0.21 0.010 OUTLET Mcum (mg/DNm3) 18.4 17.9 17.3 17.0 16.3 15.7 14.7 13.8 10.0 V (pmA) 15.1 6.59 2.55 1.29 0.74 0.41 0.23 0.767 TABLE A-7. INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN #8 IMPACTOR STAGE NUMBER Precutter 1 2 3 4 5 6 7 Filter Sample Volume (DNm3) INLET M cum (mg/DNm3) 882 821 787 749 710 621 338 227 128 d pc CumA) 40.8 3.49 2.00 1.10 0.67 0.37 0.21 0.018 OUTLET M cum (mg/DNm3) 20.5 18.5 18.5 18.5 18.5 18.0 16.9 14.4 10.3 d PC CumA) 14.6 6.41 2.48 1.25 0.72 0.40 0.23 0.390 TABLE A-8. INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN #9 IMPACTOR STAGE NUMBER Precutter 1 2 3 4 5 6 7 Filter Sample Volume (DNm1) INLET Mcum (mg/DNm3) 829 796 784 778 739 596 332 183 129 d PC CumA) 32.7 2. -80 1.61 0.89 0.53 0.29 0.17 0.033 OUTLET Mcum (mg/DNm3) 22.7 21.7 21.6 21.3 21.1 20.6 20.4 18.8 14.8 V CvmA) 14.2 6.23 2.41 1.22 0.70 0.38 0.22 0.695 ------- TABLE A-9. INLET AND OUTLET SAMPLL PARTICLE DATA FOR RUN #10 TABLE A-ll.INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN 112 IMP ACTOR STAGE NUMBER Precutter 1 2 3 4 5 6 , 7 Filter Sample Volume (DNm3) INLET M cum (mg/DNm3) 1040 885 885 859 792 549 305 189 116 d pc CumA) 32.4 2.77 1.59 0.88 0.53 0.29 0.17 0 . 0 34 OUTLET M cum (mg/DNm3) 19.3 18.7 18.7 18.7 18.7 18.3 17.2 14.8 11.5 a v (limA) 14.4 6.32 2.44 1.23 0.71 0.39 0.22 0.948 IMP ACTOR STAGE NUMBER Precutter I 2 3 4 5 6 7 Filter Sample Volume (DNm3) INLET Mcum (mg/DNm3) 1210 912 898 875 812 647 296 155 91.2 V (vmA) 35.8 3.06 1.76 0.97 0.58 0.32 0.19 0.022 OUTLET Mcum (mg/DNm3) 36.9 36.0 35.5 33.8 32.8 32.0 30.6 28.0 22.4 V CumA) 14.9 6.52 2.52 1.27 1.73 0.40 0.23 0.903 1/1 TABLE A-10. INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN #11 TABLE A-12. INLET AND OUTLET SAMPLE PARTICLE DATA FOR RUN #13 IMPACTOR STAGE NUMBER Precutter 1 2 3 4 5 6 7 Filter Sample Volume (DNm3) INLET Mcum (mg/DNm3) 863 771 771 766 735 500 273 150 99.1 d pc CumA) 31.8 2.72 ] .56 0.86 0.52 0.29 0.17 0.041 OUTLET Mcum (mg/DNm3) 31.0 27.6 27.0 26.3 25.3 24.2 22.5 19.3 14.5 V CumA) 14.5 6.35 2.46 1.24 0.71 0.39 0.23 0.928 IMP ACTOR STAGE NUMBER Precutter 1 Z 3 4 5 6 7 Filter Sample Volume (DNm3) INLET Mcu» (mg/DNm3) 1000 912 905 883 832 647 371 207 134 d PC CumA) 35.8 3.06 1.76 0.97 0.58 0.32 0.19 0.028 OUTLET Mcum Cmg/DNm3) 27.3 25.7 25.5 25.2 24.2 23.2 22.1 19.5 15.2 Sc CumA) 14.5 6.34 2.45 1.24 0.71 0.39 0.23 0.612 ------- 5.0 0.1 10 20 30 40 50 60 70 80 MASS PERCENT UNDERSIZE 90 95 5.0 0.1 10 20 30 40 50 60 70 80 MASS PERCENT UNDERSIZE 95 Figure A-l. Inlet and outlet size distribution for run »1. Figure A-2. Inlet and outlet size distribution for Run #2. ------- 5.0 0.1 10 20 30 40 50 60 70 80 MASS PERCENT UNDERSIZE 90 95 Figure A-3. Inlet and outlet size distribution for run #4. 5.0 0.1 20 30 40 50 60 70 80 MASS PERCENT UNDERSIZE 90 95 Figure A-4. Inlet and outlet size distribution for run 15. ------- 0.1 20 30 40 50 60 70 80 MASS PERCENT UNDERSIZE 90 95 S.O 1 2.0 w 1.0 S 0.5 o 8 0.2 0.1 10 20 30 40 50 60 70 80 MASS PERCENT UNDBRSIZE 90 95 Figure A-5. Inlet and outlet size distribution for run #6. Figure A-6, Inlet and outlet size distribution for run #7. ------- 5.0 0.1' 10 20 30 40 50 60 70 80 MASS PERCENT UNDERSIZE 90 95 Figure A-7. Inlet and outlet size distribution for run #8. 0.1 10 20 30 40 50 60 70 80 MASS PERCENT UNDERSIZE 90 95 Figure A-8. Inlet and outlet size distribution for run #9. ------- 5.0 5.0 0.1 10 20 30 40 50 60 70 80 MASS PERCENT UNDERSIZE 95 0.1 10 20 30 40 50 60 70 80 90 95 MASS PERCENT UNDERSIZE Figure A-9. Inlet and outlet size distribution for run #10. Figure A-10. tnlfet and outlet size distribution for run #11. ------- s:o 2.0 nl a. OS If) ta 1-u H § 0.2 0.1 10 20 30 40 50 60 70 80 m.SS PERCENT UNDERSIZE 90 95 Figure A-ll. Inlet and outlet size distribution for run #12. s.o m 0.1 20 30 40 50 60 70 80 MASS PERCENT UNDERSIZE 90 95 Figure A-12. Inlet and outlet size distribution for run #13. ------- 0.3 0.02 20 50 80 NUMBER PERCENT UNDERSIZE 95 Figure A-13. Size distributions from diffusion battery data. 42 ------- APPENDIX B VENTURI SCRUBBER PERFORMANCE MODEL 43 ------- VENTURI SCRUBBER PERFORMANCE MODEL Calvert, et al., 1976 have performed a literature review and evaluation of all available venturi scrubber performance models. Their conclusions and recommended performance model are presented below. (1) Even though each investigator presented a dif- ferent equation for the prediction of particle collection in a venturi scrubber, most of these equations can be reduced to the same basic model, i.e., fz 3 u Q n -in Pt (d ) - / 2 u (; I j . dz (B-l) o G G r d where Pt(d ) = penetration for particles with diameter d , fraction u = relative velocity between dust and drop, cm/sec UG = gas velocity, cm/sec d^ = drop diameter, cm n = single drop collection efficiency, fraction Q - liquid volumetric flow rate, cm3/sec z = length, cm (2) A generalized method for applying equation B-l to predict particle collection in a venturi was developed. (3) Particle collection predicted by equation B-l agrees satisfactorily with performance data. (4) Most of the particle collection occurs in the venturi throat. The solution to equation B-l for the venturi throat, using the inertial collection efficiency correlation, and assuming a zero initial drop velocity, is 44 ------- B -[• - 5.02 po \ d. i. po t 1 + f\ 7 4 K™ + 4-2 - 5.02 Kpo + *177 L P° (B-2) where u - 2 l - Pt(d ) = penetration for particles with diameter d , fraction B = Q. = volumetric liquid flow rate, cm3/sec PT = liquid density, g/cm3 PG = gas density, g/cm3 Cn = drag coefficient obtained from the "standard curve" Do ° u5 - dimensionless drop velocity u, = »Gt u, = drop velocity, cm/sec UG = gas velocity in the throat, cm/sec K = inertial parameter based on throat velocity - C' dP PP "Gt 9 yr d, b u 45 ------- C1 = Cunningham slip factor d = particle diameter, ym p - particle density, g/cm3 PP = gas viscosity, poise d, = drop diameter, cm L = dimensionless throat length L = 3 *t So PG 2 dd PL Equation B-2 slightly under estimates the particle collection occurring in a venturi scrubber. For most industrial venturi scrubbers, particle collection can be predicted closely by neglecting the first term in the right hand side of equation B-2. (5) Pressure drop predictions by the modified Calvert's equation and by Boll's equation agree with experimental data. The modified Calvert's equation has the following form, AP = 1.03 x 10 3 Fj u * «i (B-3) where AP = pressure, cm W.C. uGt = gas velocity i-n tne throat, cm/sec Qj = liquid flow rate, cm3/sec QG = gas -flow rate, cm3/sec F! = correction factor, dimensionless Fl = = 2 l - X2+ &- X) 20'5 uGt v * *tCDo PG . , 16 d P 46 ------- ude = drop velocity at the exit of the throat, cm/sec 5, = throat length or distance between liquid injection point and the exit of throat, cm d, = drop diameter, cm PG = gas density, g/cm3 PL = liquid density, g/cm3 C~ = drag coefficient at the liquid injection point. (6) The use of a drag coefficient from the "Standard curve" gives a better fit between model and experimental data than does Ingebo's correlation. (7) The drop diameter can be assumed to be the Sauter mean diameter calculated from the Nukiyama-Tanasawa relation. Reference: Calvert, S., S. Yung and H.F. Barbarika, "Venturi Scrubber Performance Model," A.P.T., Inc., EPA Contract No. 68-02-1328, Task 13, July 1976. 47 ------- TECHNICAL REPORT DATA (Please read Instructions on the reverse before completing) 1. REPORT NO. EPA-5::/2-77-2C9b 2. 3. RECIPIENT'S ACCESSION NO. 4. TITLE AND SUBTITLE American Air Filter Kinpactor 10 x 56 Venturi Scrubber Evaluation 5. REPORT DATE November 1977 6. PERFORMING ORGANIZATION CODE 7. AUTHOR(S) Seymour Calvert, Harry Barbarika, and Gary M. Monahan ^ 8. PERFORMING ORGANIZATION REPORT NO. 9. PERFORMING ORGANIZATION NAME AND ADDRESS Air Pollution Technology, Inc. 4901 Morena Boulevard, Suite 402 San Diego, California 92117 10. PROGRAM ELEMENT NO. IAB012; ROAP 21ADM-029 11. CONTRACT/GRANT NO. 68-02-1869 12. SPONSORING AGENCY NAME AND ADDRESS EPA, Office of Research and Development Industrial Environmental Research Laboratory Research Triangle Park, NC 27711 13. TYPE OF REPORT AND PERIOD COVERED 13. TYPE OF REPORT AND Final; 8/76-10/77 14. SPONSORING AGENCY CODE EPA/600/13 15. SUPPLEMENTARY NOTES IERL-RTP project officer for this report is Dale L. Harmon, Mail Drop 81, 919/541-2925. 16. ABSTRACT The report gives results of an evaluation of an American Air Filter Kinpac- tor 10 x 56 venturi scrubber, operating on emissions from a large borax fusing fur- nace. Average total efficiency was 97. 5% during the test period. The venturi was operated at a pressure drop of 110 cm W.C. , using about 33 liters/s o.f scrubbing liquor for a gas flow rate of about 20 A cu m/s (43,000 CFM) at 80 C. The dust had a mass median aerodynamic diameter of about 0.8 micrometers A. The collec- tion efficiencies of particles with aerodynamic diameters between 0.3 and 3 micro- meters A were determined from size distribution data taken with cascade impactors. The efficiency data showed the venturi to be more efficient than predicted for par- ticle sizes below 1 micrometer A. Particle mass augmentation by condensed water is a probable reason for the high efficiency for small particle collection. Diffusion battery data indicate the occurrence of some particle growth. 7. KEY WORDS AND DOCUMENT ANALYSIS DESCRIPTORS b.lDENTIFIERS/OPEN ENDED TERMS COS AT I Field/Group Air Pollution Scrubbers Venturi Tubes Borax Fusion (Melting) Furnaces Dust Air Pollution Control Stationary Sources Venturi Scrubbers Kinpactor Fusing Furnace 13B 07A 14B 08G,07B 20M 13A 11G 3. DISTRIBUTION STATEMENT Unlimited 19. SECURITY CLASS (ThisReport) Unclassified 21. NO. OF PAGES 56 20. SECURITY CLASS (This page) Unclassified 22. PRICE EPA Form 22ZO-1 (9-73) 48 ------- |