United States Industrial Environmental Research EPA 600 7 78 098
Environmental Protection Laboratory June 1978
Agency Research Triangle Park NC 27/11
Particulate Control
Mobile Test Units:
Third Year's Operation
Interagency
Energy/Environment
R&D Program Report
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental Protec-
tion Agency, have been grouped into nine series. These nine broad categories were
established to facilitate further development and application of environmental tech-
nology. Elimination of traditional grouping was consciously planned to foster technology
transfer and a maximum interface in related fields. The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the ENVIRONMENTAL PROTECTION TECHNOLOGY
series. This series describes research performed to develop and demonstrate instrumen-
tation, equipment, and methodology to repair or prevent environmental degradation from
point and non-point sources of pollution. This work provides the new or improved tech-
nology required for the control and treatment of pollution sources to meet environmental
quality standards.
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 Informa-
tion Service. Springfield. Virginia 22161
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EPA-600/7-78-098
June 1978
Particulate Control Mobile Test Units:
Third Year's Operation
by
t
Donald L Zanders
Monsanto Research Corporation
1515 Nicholas Road
Dayton, Ohio 45407
Contract No. 68-02-1816
ROAPNo. 21ADM-034
Program Element No. 1AB012
EPA Project Officer: C. Victor Briscoe
Industrial Environmental Research Laboratory
Office of Energy. Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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ABSTRACT
This report summarizes the third year of operation for EPA-owned
mobile test units. Unlike prior reports1'2, detailed field test
results are not included.
Three field units (baghouse, wet scrubber, and electrostatic pre-
cipitator) are designed to be used for studying the applicability
of different methods for controlling fine particulate emitted
from a wide variety of sources. A fourth unit (Energy Van) is
designed to demonstrate the feasibility of unconventional energy
supply systems to support residential and commercial buildings.
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CONTENTS
Abstract ii
Figures iv
Acknowledgements viii
1. Introduction and Objectives 1
2. Review of Operations 4
Baghouse Unit 4
Mobile Scrubber Unit 11
Mobile Electrostatic Precipitator 16
Mobile Energy Van 18
j
3. References 21
111
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FIGURES
Number Paqt
1 Current baghouse enclosure 7
2 End view - baghouse 7
3 Average mass penetration vs geometric mean
particle diameter 10
4 External view of mobile scrubber unit 13
5 Mobile scrubber unit process area 14
6 Sieve tray column 15
7 Electrostatic precipitator processing unit -
exterior view 17
8 Electrostatic precipitator processing unit -
interior view 17
9 Energy van - side view 20
10 Energy van - interior living area 20
11 Energy van - fuel delivery system 20
IV
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SECTION 1
INTRODUCTION AND OBJECTIVES
The purpose of EPA Contract No. 68-02-1816 is to provide the
operational- effort required to obtain field laboratory and pilot
plant test data from EPA-owned equipment and systems. Contract
operations are divided into four areas:
MOBILE TEST UNITS
Mobile test units on the contract consist of truck-mounted items
i
of conventional dust collection equipment: fabric filter,
venturi scrubber, sieve tray scrubber, and electrostatic precipi-
tator. Program objective is to assess the ease/difficulty in
controlling particulate-laden gas streams by these items of
equipment.
AERODYNAMIC TEST CHAMBER
This wind-tunnel-like chamber provides for gas movement in a wide
range of velocities at temperatures from ambient to above 149°C
(300°F) and accommodates a broad spectrum of gas composition and
particulate loading. The test chamber is used primarily for
calibration and testing of fine particulate measurement equipment
and as a dust source for the mobile field units.
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PILOT SOV SCRUBBERS
X
Twin 23-cm (9-inch) diameter glass column scrubbers and associ-
ated support equipment comprise this pilot unit. Objectives are
to determine quick, easy, inexpensive solutions to operating and
technical problems encountered in the development of full-size
SO scrubbing systems.
JL
ENERGY VAN
The EPA Energy Van is a towable mobile home containing an energy
supply system that utilizes environmentally clean and energy-
conserving components. These components include fuel cells, a
solar energy collector, a heat pump, and catalytic appliances.
The objective of the mobile system is to develop and demonstrate
an energy supply system for residential and commercial buildings
which could cut pollution and energy consumption by as much as
50%.
The aerodynamic test chamber and pilot scrubber system are perma-
nent installations at the National Environmental Research Center
(NERC) in Research Triangle Park, North Carolina. Although the
truck-mounted units use this location as a service base, the
majority of their operating time is spent in the field at various
plant sites throughout the country. The energy van is currently
located at the NERC for performance testing.
The four operational areas represent, to varying degrees, differ-
ent program interests and groups or sections within the Industrial
Environmental Research Laboratory. The contractor's objective is
to fulfill the needs of each interest within the contract scope.
Thus, the level of involvement varies in each operational area.
For example, in the areas of the aerodynamic test chamber and
pilot SO scrubbers, the activities of program and test planning
A
and interpretation of results are primarily conducted by EPA
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personnel. In the mobile test unti area, however, the contractor
is also largely responsible for developing the test plans and
interpreting results obtained.
This report primarily summarizes activities of the mobile bag-
house, wet scrubbers, electrostatic precipitator and energy van
during the third contract year.
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SECTION 2
REVIEW OF OPERATIONS
BAGHOUSE UNIT
Background
The mobile fabric filter system (baghouse unit) was designed and
fabricated by GCA/Technology Division, Bedford, Massachusetts.
The unit was mounted on a 1.36-metrie-ton (IVton) truck and is
described at length in GCA reports. Briefly, it has the follow-
ing capabilities:
• Filtration can be conducted at cloth velocities as high
as 0.102 m/s (20 fpm) with a pressure differential up to
4.98 kPa (20 in. water) and at a gas temperature up to
288°C (550°F).
• The mobile system is adaptable to cleaning by mechanical
shaking, pulse jet, or low pressure reverse flow, with
cleaning parameters which vary over broad ranges.
• The system can be operated in a series filtration mode.
• One to seven filter bags of any medium, 1.22 m to 3.05 m
(4 ft to 10 ft) long and up to 0.3 m (12 in.) in diameter,
can be used.
• Automatic instruments and controls enable 24-hour opera-
tion of the system.
4
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After brief field tests, the unit was delivered to contractor
personnel for use in a field testing program for the Industrial
Environmental Research Laboratory of EPA.
For several reasons, the baghouse unit, as received, required
preliminary "dry run" testing at the RTF Environmental Research
Center, and intensive shakedown tests in the field under severe
conditions. The dry run tests at RTF were directed at opera-
tional checks of system components and training of new operators.
The unit was then given shakedown tests in the field on a pulp
mill lime recovery kiln. After a brief return to RTF for refur-
bishing, the unit was taken to Sunbury, Pennsylvania for tests on
Pennsylvania Power and Light Company's Shamokin Dam, coal-fired
generating station on 16 December 1974. These tests lasted
through 26 February 1975.
t
On completion of these tests, about two months were required to
refurbish the unit and sample trains, after which the unit was
placed at a lime recovery kiln at Weyerhauser Corporation's
pulp mill in Plymouth, North Carolina from 21 April 1975 to
19 September 1975.
After conclusion of testing at the Weyerhauser pulp mill, the
baghouse was returned to Research Triangle Park, North Carolina
for a complete repackaging and refurbishing effort.
As received, the baghouse unit was mounted in a 1.36-metric-ton
(1.5-ton), stake bed truck. Portions of the system were relo-
cated for operation outside the truck bed due to the truck size.
This mode of operation turned out to be extremely inconvenient
and detrimental to efficient field testing. Therefore, it was
decided to mount the entire baghouse system in a 12.2-m (40-ft)
tractor trailer unit.
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The trailer unit was purchased and delivered on 30 January 1976,
and repackaging commenced. In addition to transfer of the system
to the trailer, potential solutions to a number of operational
problems encountered during field operations were incorporated.
Figures 1 and 2 show the current baghouse unit.
Third Year Testing
Completion of the repackaging effort was accomplished in August
1976 and the unit was taken to the field during the first half
of November for tests on a refuse processing plant in St. Louis,
Missouri.
St. Louis Testing
A baghouse field test was conducted 8 through 11 November 1976 at
the city of St. Louis refuse processing plant. The baghouse was
fed with a slip-stream installed on the plant's air density sepa-
rator (ADS) cyclone exhaust duct. Pulse jet cleaning and felted
Dacron polyester bags were used. Data were gathered on baghouse
operation, inlet and outlet particulates mass, and inlet and
outlet particle size.
Slipstream flow rate was 3.11-3.26 actual m3/m (110-115 acfm)
with a bag air-to-cloth ratio of 1.43-1.49 m/m (4.7-4.9 fpm).
Bag cleaning was a problem due to the linty character of the
plant's emissions. During operation, increased bridging between
the bags was experienced. Changing cleaning interval and pulse
duration did not improve cleaning. This observation suggests
that the felted bags, bag spacing, and/or pulse cleaning may not
be appropriate for the material from this source.
All individual samples on the baghouse inlet were invalid due to
sample nozzle plugging. Inlet mass concentration was derived
from the baghouse material collected and averaged 3.47 g/dsm3
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Figure 1. Current baghouse enclosure.
. -
Figure 2. End view - baghouse,
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(0.13 grain/dscf) over the three days in which outlet sampling
was conducted. Extremely low baghouse outlet particulate concen-
tration forced outlet samples to be extended over three days of
operation. The measured outlet total mass concentration was
1.79 x 10~3 g/dsm3 (6.7 x 10~5 grains/dscf). The resulting mass
penetration was 0.05% (99.95% efficiency). Outlet particle size
measurements showed 80% of the outlet mass smaller than 8 pm
aerodynamic diameter (assuming 1 g/cc particle density) and a
mass median diameter of 4 pm.
Baghouse fractional efficiency was estimated using previous par-
ticle size measurements by Midwest Research Institute on the ADS
cyclone exhaust duct. The results indicate a bimodal fractional
efficiency curve between 1 and 20 pm. The penetration reaches a
maximum of 2% between 3 and 4 pro aerodynamic diameter; this size
range represents less than 1% of the total inlet mass.
The unit performed exceptionally well in its first field test
and was returned to Research Triangle Park for reconditioning
and storage for the next field test.
Amarillo, Texas Test
Low sulfur western coal is being increasingly used to produce
electricity and reduce sulfur dioxide emissions. Burning this
coal, however, presents problems in applying electrostatic pre-
cipitators for particulate control.
To gather data on the applicability of baghouses for removing the
particulate matter from such an installation, the mobile baghouse
was taken to the Harrington Station of Southwestern Public
Service Company (SPSCo), Amarillo, Texas, in April 1977.
Harrington Station has one 265 MW unit on-line burning low sulfur
Wyoming coal. Objectives of the test were to obtain baghouse
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operating data and information as well as particle collection
capabilities on total mass and different particle sizes. Testing
was conducted over a three-month period.
Total particulate mass sampling was conducted at the inlet and
outlet of the baghouse. Both teflon/glass and graphite/glass
bags were tested in two different cleaning modes — reverse air
and shake. Average total mass removal efficiencies were as shown
in Table 1. Inlet concentrations generally increased with in-
creasing boiler load, but the data showed no clear correlation.
For all bag types, mass penetration decreased with increasing
inlet mass concentration.
TABLE 1. TOTAL MASS REMOVAL EFFICIENCIES
Bag type
Teflon/glass
Teflon/glass
graphite/glass
graphite/glass
Cleaning mode
shake
reverse air
shake
reverse air
Removal
efficiency, %
99.83
99.90
99.96
99.97
The graphite/glass bags performed better under test conditions
than the teflon/glass in either cleaning mode.
Inertial cascade impactors were employed for particle size deter-
minations. Brinks® impactors were used for inlet size distribu-
tions and Anderson® impactors for outlet size distributions.
Figure 3 shows mass penetration versus particle size curves
developed from averages of several size distribution measurements
conducted. All four penetration curves shown exhibit minima.
All curves show increasing penetration with decreasing particle
size below 2 urn.
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1.0
.10
o>
.01
©•
—© Teflon/Glass Shake Bags
—0 Graphite/Glass Shake Bags
—A Teflon/Glass Reverse Air Bags
•— Graphite/Glass Reverse Air Bags
fp=2.6g/cm2
0.1 .2 .4 .6 .8 1.0 2 2.5 4 t
Geometric Mean Particle Diameter, urn
Figure 3. Average mass penetration vs geometric
mean particle diameter.
8 10
10
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The graphite/glass shake mode bags had the lowest penetration
in the particle size range measured. Minimum penetration was
0.025%, 83% lower than the minimum for the teflon/glass shake
mode bags.
Current Status
After the Amarillo test was completed, the baghouse was returned
to base and awaits field assignment at this writing.
MOBILE SCRUBBER UNIT
Background
The mobile scrubber unit was designed and fabricated by the
Detection Branch, Chemical and Biological Sciences Division of
the Naval Surface Weapons Center (NSWC), Dahlgren, Virginia,
under project order No. 4-0105-(NOL)/EPA-1AG-133(D), Task 2. On
completion of construction and brief equipment checkout by NSWC,
the unit was received by the Industrial Environmental Research
Laboratory on 16 December 1974. The unit was subsequently placed
on site at Pennsylvania Power & Light Company's generating sta-
tion at Sunbury, Pennsylvania on 15 January 1975, for initial
field shakedown testing. Shortly after startup of the unit at
Sunbury, the induction fans failed and NSWC retrieved the unit
to determine the cause of failure and repair the fans.
After completion of repairs and minor modifications, the unit was
returned to IERL and taken to Research Triangle Park for exten-
sive shakedown tests under simulated field conditions. It was
then taken to Weyerhauser Corporation's pulp mill at Plymouth,
North Carolina on 21 April 1975 and hooked up to a lime recovery
kiln for execution of a test plan for evaluating dust control
efficiency of the two types of scrubbers involved (venturi and
sieve tray). Before a week of operation under field conditions
was completed, the induction fans failed once more.
11
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After the fans had failed for the second time, the scrubber unit
was returned to Research Triangle Park, North Carolina for modifi-
cations. New fans of a different design were selected, purchased
and installed in the scrubber unit. These items were received
from the vendor during January 1976.
Carryover liquid had also been noted as an operational problem
with the scrubber system, and the decision was made to replace
the mist eliminator with another unit of different design to try
and minimize this occurrence.
A third bothersome operational problem involved activation of
automatic shutdown sequence due to false signaling from the sump
tank overflow protection system. The cause turned out to be
entrained mist. This problem was remedied by design change.
After the new equipment had been installed, the scrubber unit was
subjected to simulated field testing at Research Triangle Park
for two weeks. No problems surfaced during the testing, and a
concerted effort was then initiated to find a suitable testing
site.
In .mid-June 1976, arrangements were finalized to place the scrub-
ber on stream at a gray iron foundry. Testing was conducted over
a two-month period at the iron foundry, and the unit was then
returned to Research Triangle Park, North Carolina where it is
in storage at this writing. Figures 4, 5, and 6 illustrate the
scrubber unit configuration.
Iron Foundry Testing
While field testing at the iron foundry was completed by
September 1976, urgent priorities have prevented test evaluation
and reduction to reportable form over the period covered by this
report. Such information will likely be summarized in the fourth
annual operations report.
12
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* '
Figure 4. External view of mobile scrubber unit.
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Figure 5. Mobile scrubber unit process area.
14
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Figure 6. Sieve tray column.
15
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MOBILE ELECTROSTATIC PRECIPITATOR
Background
The mobile electrostatic precipitator was designed and fabricated
by the Naval Surface Weapons Center, Dahlgren, Virginia for the
Industrial Environmental Research Laboratory of EPA. This unit
is the largest of the three mobile pilot-scale units and is
mounted in two 3.05-m (40-ft) trailers. One trailer contains the
processing unit and the other the control panel, plus an area
designed for sample processing and associated laboratory work.
Figures 7 and 8 show the interior and exterior of this unit.
Pickup of the unit from the Naval Surface Weapons Laboratory
was accomplished in October 1976, when it was transported to
Research Triangle Park, North Carolina.
In mid-December 1976, the electrostatic precipitator was prepared
for on-site checkout testing using the EPA wind tunnel as a
source of dust-laden test gas. These shake-down operations were
completed by mid-January 1977 and preparations were initiated im-
mediately for field testing on a refuse-derived fuel/coal mixed
feed industrial boiler at Eagerstown, Maryland. Preparations
included designing and fabricating additional inlet gas ductwork
needed to properly draw off the necessary gas slipstream for
testing.
Testing was conducted for two weeks in Maryland to gather data
on the effect of refuse-derived fuel combustion product dust on
electrostatic precipitator particulate removal efficiency. The
program was judged successful, based upon a preliminary evaluation
of results; however, other sampling priorities have prevented
reduction of the results to report form to date. Such results
will likely appear in the next annual report.
16
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cook, light, operate appliances, and refrigerate within the van.
Figures 9 through 11 illustrate the van configurations.
Objectives in building the van were to develop and demonstrate an
energy supply system which cuts pollution and energy consumption
by as much as 50% for residential and commercial buildings.
This mobile unit was acquired by the contractor on 21 June 1976.
A test plan was written for a one year testing program to be con-
ducted at the National Environmental Research Center, Research
Triangle Park, North Carolina, in the hope of beginning testing
during August of that year. Included in the test plan was a com-
plete safety audit of the unit prior to testing.
The safety audit revealed a number of items judged to be hazard-
ous to operators by the inspection team. In consideration of
this judgement, van testing was ,held in abeyance until a modifi-
cation plan could be defined and fully implemented. In the
interim, a three-week limited operation test was conducted during
December 1976, using only the solar panel and associated equip-
ment. During this test period, outside temperatures remained
generally below -6.7°C (20°F), yet heat derived from the solar
panel and associated thermal energy storage system was sufficient
to maintain living area temperature at least as high as 20°C
(68°F) except for one period where no direct sunlight was avail-
able over a 48-hour period.
A final resolution of the safety modification plan was accom-
plished in March 1977 and work began on modification. At the
end of the operating period covered by this report (30 June 1977)
work was still in progress.
19
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Figure 9. Energy van - side view.
Figure 10.
Energy van - interior Figure 11
living area.
Energy van - fuel
delivery system.
20
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SECTION 3
REFERENCES
1. Hall, R. Mobile Fabric Filter System - Design Report.
GCA/Technology Division. Contract No. 68-02-1075. October
1974.
2. Hall, R. Mobile Fabric Filter System - Final Report.
GCA/Technology Division. Contract No. 68-02-1075. May
1975.
21
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing}
1. REPORT NO.
EPA-600/7-78-098
2.
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Particulate Control Mobile Test Units: Third Year's
Operation
5. REPORT DATE
June 1978
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Donald L. Zanders
8. PERFORMING ORGANIZATION REPORT NO.
MRC-DA-783
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Monsanto Research Corporation
1515 Nicholas Road
Dayton, Ohio 45407
10. PROGRAM ELEMENT NO.
1AB012; ROAP 21ADM-034
11. CONTRACT/GRANT NO.
68-02-1816
12. SPONSORING AGENCY NAME ANO ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Annual: 6/76-6/77
14. SPONSORING AGENCY CODE
EPA/600/13
is. SUPPLEMENTARY NOTES T£RL-RTP project officer is C. Victor Briscoe, Mail Drop 60,
919/541-2882. EPA-600/2-77-042 and -76-042 are earlier reports in this series.
is. ABSTRACT
report summarizes the third year's operation of EPA-owned mobile
test units. Unlike prior reports , detailed field test results are not included. Three
field units (the baghouse, wet scrubber, and electrostatic precipitator) are designed
to be used for studying the applicability of different methods for controlling fine par-
ticulate emitted from a wide variety of sources. The fourth unit (an energy van) is
designed to demonstrate the feasibility of unconventional energy supply systems to
support residential and commercial buildings.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Air Pollution
Dust
Mobile Equipment
Tests
Fabrics
Gas Filters
Gas Scrubbing
Scrubbers
Electrostatic Pre-
cipitators
Energy Conversion
Techniques
Air Pollution Control
Stationary Sources
Particulate
Baghouses
Fabric Filters
13B
11G
15E
14B
HE
13K
07A,13H
131
10A
3. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report}
Unclassified
21. NO. OF PAGES
26
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
22
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