EPA-650/2-74-036
May 1974
                             Environmental Protection  Technology  Series
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                                    EPA-650/2-74-036
BRAXTON  SONIC  AGGLOMERATOR
               EVALUATION
                       by
            Richard Dennis , Robert Bradway ,
                   and Reed Cass

                  GCA Corporation
               GCA/Technology Division
              Bedford, Massachusetts  01730
             Contract No. 68-02-1316 (Task 1)
                 ROAP No. 21ADL-04
              Program Element No. 1AB012

             EPA Task Officer: Dale Harmon
              Control Systems Laboratory
          National Environmental Research Center
        Research Triangle Park, North Carolina 27711
                    Prepared for
         OFFICE OF RESEARCH AND DEVELOPMENT
        U.S. ENVIRONMENTAL PROTECTION AGENCY
               WASHINGTON,  D.C. 20460

                     May 1974

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This report has been reviewed by the Environmental Protection Agency
and approved for publication.  Approval does not signify that the
contents necessarily reflect the views and policies of the Agency,
nor does mention of trade names or commercial products constitute
endorsement or recommendation for use.
                                  11

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                                   ABSTRACT

     This report presents the evaluation of a novel air pollution control
system developed by the Braxton Corporation.  The alternating velocity
precipitator, or sonic agglomerator, is designed to decrease the number
and increase the size of particles in a gas stream by agglomeration in-
duced by a standing sound wave through which the aerosol moves.  A proto-
type unit of the alternating velocity precipitator was tested to determine
its basic performance characteristics and to evaluate the effect of the
addition of water and/or steam to the system's performance.
     Results from those tests using resuspended cupola dust indicate that
the device decreases the mass of fine particles but that the reduction is
more highly correlated to the use of water sprays than to the use of the
sonic generator.  The correlation coefficients relating the use of sound
and water sprays to fine particle reduction are statistically significant
but the correlation coefficient for steam addition is not statistically
significant.
     The particle size distributions of the fine particles at both the inlet
and outlet of the sonic agglomerator were determined with Andersen cascade
impactors.   Although shifts between the inlet and outlet size distributions
were often observed, there was no clear trend to the changes and they could
not be correlated to system operating parameters.
                                      111

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                              CONTENTS




                                                                Page




Abstract                                                         iii




List of Figures                                                  v




List of Tables                                                   vii




Acknowledgments                                                  viii




Sections




I        Conclusions                                              1




II       Recommendations                                          3




III      Introduction                                             4




IV       Sampling Methods                                         6




V        Analysis Methods                                        10




VI       Results                                                 11




VII      Appendices                                              44
                                 IV

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                               FIGURES

 No.                                                              page

  1      Schematic of Sampling Train                                7

  2      Effect of Water Flow Rate on the Reduction
        of Fine Particles                                         17

  3      Effect of Steam Flow Rate on the Reduction
        of Fine Particles                                         18

  4      Effect of Sonic Generator Power Consumption
        on Reduction of Fine Particles                            20

  5     Particle  Size Distribution of  Cyclone Undersize Dust
       for Test  1                                                 23

  6     Particle  Size Distribution(s)  of Cyclone Undersize
       Dust  for  Test 2                                            2.4

  7     Particle  Size Distribution of  Cyclone Undersize Dust
       for Test  3                                                 25

 8     Particle  Size Distribution(s)  of Cyclone Undersize
       Dust  for  Test: 4                                            26

 9     Particle  Size Distribution(s)  of Cyclone Undersize
       Dust  for  Test 5                                            27

10     Particle  Size Distribution(s)  of Cyclone Undersize
       Dust  for  Test 6                                            28

11     Particle  Size Distribution(s) of Cyclone Undersize
       Dust  for  Test 7                                            29

12     Particle  Size Distribution(s) of Cyclone Undersize
       Dust  for  Test 8                                            30

13     Particle  Size Distribution(s) of Cyclone Undersize
       Dust  for  Test 9                                            31

14     Particle  Size Distribution(s) of Cyclone Undersize
       Dust  for  Test 10                                           32

15     Particle  Size Distribution(s) of Cyclone Undersize
       Dust  for  Test 12                                          33

16     Particle  Size Distribution(s) of Cyclone Undersize
       Dust  for Test 13                                          34

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                         FIGURES (continued)


No.                                                             Page

17     Particle Size Distribution(s) of Cyclone Undersize
       Dust for Test 14                                          35

18     Particle Size Distribution(s) of Cyclone Undersize
       Dust for Test 15                                          36

19     Particle Size Distribution(s) of Cyclone Undersize
       Dust for Test 16                                          37

20     Particle Size Distribution(s) of Cyclone Undersize
       Dust for Test 17                                          38

21     Particle Size Distribution(s) of Cyclone Undersize
       Dust for Test 18                                          39

22     Effect of AVP System on Mass Median Diameters of
       Cyclone Undersize Dust                                    41
                                 VI

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                               TABLES

No.                                                             Page

 1     Sonic Agglomerator System Operating Parameters            12

 2     Comparison of Inlet and Outlet Dust Loading, Cyclone
       Catch, Cyclone Undersize Dust and Overall System
       Collection of all Particle Sizes                          14

 3     Comparative Concentration Measurements of Cyclone
       Undersize Dust with Glass Fiber Filters and Andersen
       Impactors                                                 22

 4     Estimated Operating Costs of AVP System                   43
                               vii

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                           ACKNOWLEDGMENTS

The information and support provided by Mr. Ed Kent and the Braxton
staff are acknowledged with sincere thanks.
                               viii

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                                  SECTION I
                                 CONCLUSIONS

    The prototype  sonic agglomerator tested in  this program collected 42  to
59 percent of the  test dust entering it without the use of sound, water or
steam.  The collection efficiencies using resuspended cupola dust and dif-
ferent combinations of sound, steam and water ranged from 81 to 97 percent.
These efficiencies are based on using a cyclone after the sonic agglomerator
equal in collection efficiency to the cyclone used for sampling during these
tests.
    The amount of  fine particles, as defined by the cyclone undersize dust
(less than about 2 ^m), was measured upstream and downstream of the chamber
and the use of sound and water sprays reduced the fine fraction at thp out-
let.  The reduction in fine particles as a result of conditioning by the
sonic agglomerator system under various operating modes ranged from 14 to
83 percent.
    The correlation coefficients for the small particle reduction for all
test runs with sound, water and steam individually and neglecting other
operating parameters were 0.68, 0.65 and 0.06 respectively.   The coef-
ficients for sound and water are statistically significant while that for
steam is not.  A multiple regression analysis of those tests using cupola
dust shows that the use of steam is not significant but that the use of
water sprays and the sonic generator are highly significant in reducing the
mass of fine particles.   The regression analysis also shows that the sonic
generator has less influence on fine particle reduction than does water
sprays when using resuspended cupola dust.
    Cascade impactor samples of the cyclone undersize material at the inlet
and outlet of the unit showed no consistent trend in the shift of particle
size distributions.  Some tests resulted in an outlet dust with a larger mass
median diameter than the inlet dust, others resulted in an outlet dust with
a smaller mass median diameter than the inlet, and some tests showed no
change.   These results do not appear to correlate with any system operating
parameters.

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     The estimated annual operating costs for the sonic agglomerator system
using sound and water is $13.30/nr/minute ($0.38/cfm).  The use of a nominal
amount of steam in addition to sound and water results in an annual operating
cost of $46.22/m3/minute ($1.32/cfm).  These estimates are based upon the
costs of 1,000/nr*/minute (35,000 cfm) unit and do not include any annualized
capital costs.

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                                SECTION II
                              RECOMMENDATIONS

    This program was limited to the field evaluation as described in this
report.  It was not within the scope of the program to make specific recom-
mendations concerning the sonic agglomerator system design or ultimate use.
It is recommended, however, that if the alternating velocity precipitator ia
to become a viable part of an industrial gas cleaning system, then the sev-
eral operating parameters must be optimized.  The use of steam should be
reexamined and the optimum interaction of sound and water sprays should be
determined.  In an industrial sized unit the ultimate disposal or reuse of
the effluent base wash that contains whatever dust is retained in the chamber
must also be examined.

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                                  SECTION III
                                  INTRODUCTION

    The purpose  of  this  study was  to determine the basic performance
characteristics  of  a  sonic  agglomerator that was designed and constructed
by  the Braxton Corporation.  All  tests were performed on a prototype unit
at  the Braxton plant  in  Medfield,  Massachusetts.
    The sonic agglomerator,  or alternating velocity precipitator  (AVP),
is  designed  to impart different velocities to particles of different sizes,
hence increasing  the  probability  of collisions that result in agglomeration.
When sufficient  coagulation  occurs, the number of small particles is de-
creased through  collisions with larger ones creating a dust of large enough
particle size to  be capable  of being efficiently collected by a low energy
gas cleaning device such as  a cyclone.  A more detailed discussion of  the
theoretical basis of  acoustic coagulation is presented in Appendix A.
    Since the agglomeration  rate  should be enhanced by both a higher con-
centration and wider  size range of the inlet particulate, the system is
designed to allow the admission of steam and/or water droplets.  The steam
can be added in  the acoustical chamber or, as was done in those tests in
which steam was used  in  this study, added in the inlet duct about 50 feet
before the chamber.   This allows  the dust and steam to interact, hopefully
increasing the cohesive  properties of the dust and also raising the humidity
of  the gas to a point where  the liquid particles in the chamber will be
preserved.  The water is added as  a spray at the top of the chamber via
Sonicore nozzles.  According to the manufacturer the Sonicore nozzles de-
liver a spray in  the  10-20 p.m range.
    The chamber itself is approximately 0.75 meter (2.5 feet) in diameter
and 4.27 meters  (14 feet) in length.  The chamber length is adjustable to
enable tuning the standing sound wave which is 4~l/2 wave lengths long, so
that nodes are located at top and  bottom.   The sound wave is generated by
an electromagnetically driven piston which displaces about +0.05 cm.
(+ 0.02 inches) at a  frequency of  366 Hz.   The sound intensity inside the

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chamber is 165 decibels.  Any material that is precipitated from the gas
stream before exiting the chamber is washed off the base plate and out of
the system with a continuous flow of water.
    The prototype unit tested was designed for a maximum flow rate of
     3
7.0 m /s  (15,000 cfm).  Existing fan capabilities limited the flow to
3.7 m /s  (8,000 cfm) but most tests were run at 2.2 m /s (5,000 cfm).  At
the latter flow rate the average velocity in the chamber was 5.2 m/s (1,030
feet per minute) while at the inlet and outlet ducts (2 foot diameter) the
average velocity was 8.1 m/s (Ij600 feet per minute).
    There are several factors that could lead to particulate depletion in
the system besides the agglomeration and subsequent fallout as a result of
sonic action.  For example, there could be wash out from the water spray
system, the larger fraction entering the chamber may settle without further
coagulation because of the relatively low velocity in the chamber, or the
right angle bends at the entrance and exit of the chamber may remove some
particulate.   The test program was designed in such a way as to first es-
tablish the effectiveness of the entire system and then determine the role
of each of the components (sound, steam,  water, velocity, etc.).

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                                 SECTION IV
                              SAMPLING METHODS

     The sonic agglomerator is designed to  increase  the  size  of small  parti-
 cles and,  as  such,  is a preconditioner rather  than  a  collector.  Although
 some dust  would be  expected to remain in the sonic  chamber,  the  effective-
 ness of the device  can be determined  only  by characterizing  the  properties
 of the  outlet dust  that would make  it more readily  collectable than the
 inlet dust.   Since  the Braxton system is designed to  be  followed by a cyclone
 as a final collector, a sampling system with a  cyclone  followed  by a  filter
 would allow determination of the change in mass  of  the  cyclone undersize
 material as a result  of the conditioning system.
     To  further characterize the effectiveness of the  system, cascade  impactor
 samples  were  taken  of the cyclone undersize material  at  both the inlet and
 outlet.  This showed  any shifts in  the particle  size  distribution of  the
 fine material.
     The  sampling system used in this  study is shown schematically in  Figure 1
 and  calibrations for  specific components are detailed in Appendix B.  A
 portion  of the system flow was  withdrawn isokinetically  through a sampling
 nozzle  (a).   The nozzles were interchangeable and a set  was designed and
 manufactured  to match all flow combinations used during  the tests.  The
 sampled  gas stream  then entered the probe   (b) connecting the  nozzle and the
 cyclone.   This  probe  was one inch copper pipe and the bend before the cyclone
 was  necessitated by space limitations  at the prototype unit.   The larger
 sized dust fraction was  then separated  by  an Aerotec model 1%  cyclone (c)
 manufactured  by UOP Air  Correction.   The cyclone was also used to meter the
 flow  in  the sampling  system by  measuring the pressure drop across it with a
manometer  (d).   A variable  transformer  on  the main sampling pump was used to
 maintain 746.5  n/ 2 (3  inches water)  differential across the cyclone which
                  m       3
 corresponded  to 0.0085 m /   (18 cfm).
    The  exit  duct from  the  cyclone  (e)  was  also  one inch copper pipe with a
 small port drilled  in it about  twenty  duct  diameters downstream.  This

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                                     m
Figure 1.  Schematic of Sampling Train

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 allowed  access  for the small probe (f)  which  led  to  the  Andersen  six  stage
 cascade  impactor  (g) .   The  probe  was  designed for isokinetic  sampling and
 kept  as  short as  possible.   The collection  surfaces  of the  cascade  impactcrs
 were  coated  before use with a thin uniform  layer  of  petroleum jelly to mini-
 mize  particle bounce and reintrainment.   The  impactor was  followed  by a glass
 fiber filter (h)  and a critical orifice (i) for flow control.  Conditions
 for critical flow were monitored  by observing the upstream  pressure with a
 mercury  manometer (i)  and knowing the pump  pressure  capabilities  of the model
 0522-V3-G18D Cast pump (k).   Laboratory measurements determined that  the
 Cast  pumps used were capable of maintaining a flow rate  of  one cubic  foot
 per minute at an  absolute suction pressure of 10.2 inches of  mercury.  Since
 critical flow of  air through an orifice is achieved when the  pressure down-
 stream of the orifice  is less than or equal to 0.53 of the  upstream pressure,
 a downstream absolute  pressure of 10.2  inches of  mercury assures  that critical
 flow  will occur if the upstream absolute pressure is 19.25  inches of  mercury
 or more.  Monitoring the upstream pressure also allowed  the critical  flow-
 rate  to  be corrected to standard  conditions.
    The  cyclone undersize dust that was  not diverted through  the  impactor
 continued on to a glass fiber filter  (1).  The filter holder  was a  Precision
 Scientific model  high  volume sampler  (m)  with the inlet  modified to make a
 smooth transition from the  copper pipe  to the filter area.  The high volume
 sampler  was  the main air mover of the sampling system and the flow  rate
 through  it was controlled electrically  by a variable transformer  (n)  so that
 the pressure drop across the  cyclone  remained constant.
    The  resistance across the high  volume filter  increased quite rapidly and
 it was found that  fifteen minutes was a  safe  sampling time without over-
 extending the capabilities of the high volume sampler.    It also became appa-
 rent  after the first few runs  that  the dust concentration was apt to  fluctuate
with  time so that  it was very  important  to have simultaneous upstream and
downstream sampling.
    An Acrison 120 D dust feeder  delivered the test dust to an air ejector
which dispersed the dust into  the gas stream.   Occasionally the dust in the
hopper adhered to  the  side walls,  creating a  temporary light dust loading
in the system.  During  one  test the delivery  auger on the feeder broke and
                                     8

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 no  dust was  dispersed  at all.   Except  for  that one  test, however,  the vari-
 ations  in  dust  concentration due  to  the  dust  feeder were minimized,  if not
 eliminated,  by  simultaneous upstream and downstream sampling.
    During some of the first few  tests,  an attempt was made to traverse the
 inlet and outlet ducts, sampling at several points  in the cross section.   The
 severe space limitations at the sampling locations made this a very awkward
 procedure.  Furthermore, the sampling time restriction of fifteen minutes
 per filter necessitated disassembling the train and changing the filter in
 the middle of each run if meaningful traverses were to be made.  It was felt
 that since the sampling ports were installed at locations where velocity and
 concentration gradients were expected to be minimized, centerline sampling
would give meaningful results.   Velocity traverses indicated a smooth flow
profile and traverses with an Ikor continuous particle monitor showed no
 large concentration gradients.   The Ikor device does not measure the mass
concentration directly but measures the electron charge transfer, or tribo-
electric effect, to monitor particulate concentrations.  Measurements with
this device at the inlet of the Braxton AVP indicated  concentration variations
of less than 25 percent across  the duct and most of those variations were
thought to reflect a temporal variation of dust loading rather than a spatial
variation.

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                                SECTION V
                            ANALYSIS METHODS

    After each test run, both the inlet and outlet sampling trains were dis-
assembled and removed to a clean work area.  Any dust deposited on the inside
of the nozzle and probe before the cyclone was brushed into a tared container.
The final net weight of this dust was added to the cyclone catch.  The
cyclones were stoppered and taken back to the laboratory for cleaning.  This
was necessitated by the very laborious procedures required to quantitatively
remove the dust that did not fall into the hopper but was impinged on the
inside of the cyclone.
    Any dust deposited on the duct between the cyclone and the high volume
sampler was also brushed into a preweighed container and later added to the
filter catch.  Occasionally some particulates deposited on the walls of the
impactor sampling probe.  When this occured the dust was added to the first
stage of the impactor.
    All samples were equilibrated in an atmosphere of less than 50 percent
relative humidity at about 65 degrees before weighing.  All weighings were
done on a Mettler H-15 balance and recorded to the nearest tenth of a milli-
gram.
    Sonic agglomerator system parameters such as steam  flow rate, water flow
rate,  sound intensity and power consumption by the sonic generator were
recorded by the Braxton personnel operating the unit.
                                    10

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                                 SECTION VI
                                  RESULTS

    This  section summarizes the results of the  test  program.  Many  sonic
agglomerator operating parameters were varied during the evaluation procedure
and the effects of these variations were assessed by measuring several pro-
perties of  the inlet and outlet aerosols.  The  complete matrix of operating
variables and dust properties  is too vast to present as one unit so the data
have been divided into separate sections.
    The first section details  the system operating parameters such  as volume
flow rate,  sound intensity, rate of steam and water addition and pressure
drop across the unit.  The next section summarizes the inlet and outlet dust
loadings  in terms of total mass, cyclone fraction, reduction of total mass,
reduction in mass of fine  particles and the total system efficiency if a
cyclone were to follow the sonic device.  The third  section shows the changes
in the particle size distribution of the fine particles.  This is done to
show what changes, if any, were imparted to that portion of the dust that
penetrated the cyclone collector.  The last section  is an estimate  of operat-
                     3
ing costs of a 1000 m /min. (35,000 cfm) unit if it were to display the same
operating characteristics as the prototype unit.
    A.  SYSTEM OPERATING PARAMETERS
        Table 1 details the several sonic agglomerator system operating
parameters that were varied during the test program.   Most tests were run in
       3
the 2 m /s (5000 cfm) range as that was considered nominal for the  prototype
device.  Redispersed cupola dust and fly ash were used as test dusts.  The
cupola dust was used more than the fly ash because the high degree  of spher-
icity and possible poor wetting properties of the fly ash were expected to
have a negative influence on agglomeration.   Preliminary sizing with Andersen
impactors of the test dusts was also performed by redispersing them  in the
laboratory with an air ejector similar to the one in the Braxton dust feed
system.  The results of these  measurements (Appendix D) also indicated the
suitability of the cupola dust.
                                      11

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                                        Table  1.
                                                        Sonic Agglomerator System Operating Parameters
RUN
NO.
1
2
3
14
5
6
7
8
9
10
11
12
13
14
15"
16
I7b
18
19
DATE
10/17/73
10/17/73
10/18/73
10/24/73
11/2/73
11/13/73
11/13/73
11/19/73
11/19/73
11/29/73
1/2/74
1/2/74
1/4/74
1/4/74
1/22/74
1/22/74
2/19/74
2/19/74
2/19/74
TEST
DUST
cupola
cupola
cupola
cupola
cupola
cupola
cupola
cupola
cupola
cupola
cupola
cupola
cupola
cupola
fly ash
fly ash
cupola
fly ash
fly ash
VOLUME
FLOW
m3/s
2.22
2.22
2.22
2.22
2.23
2.23
2.23
2.47
2.48
2.48
PRESSURE DROP
ACROSS SONIC
CHAMBER
n/m2 x 10-3
2.96
2.96
2.96
2.96
1.09
1.09
1.09
1.09
1.09
1.09
DUST FEEDER FAILURE
0.82
3.72
3.72
2.48
0.82
2.47
2.47
2.47
0.12
2.53
2.53
1.09
0.12
1.09
1.09
1.09
FAN POWER8
KILOWATTS
12.40
12.40
12.40
12.40
4.94
4.94
4.94
5.48
5.50
5.50

0.20
19.19
19.19
5.50
0.20
5.48
5.48
5.48
STEAM
PRESSURE
n/n>2 x 10-3







3.45
3.45
48.26

3.45

3.45

20.68

3.45
3.45
FLOW
m3/s x 105
0
0
0
0
0
0
0
2.27
2.27
11.35

2.27
0
2.27
0
7.72
0
2.27
2.27
WATER
PRESSURE
n/m2 x lO'4

10.34
10.34
10.34
10.34
10.34
10.34
6.90
6.90
6.90



6.90



10.34
10.34
FLOW
m3/s x 105
0
8.20
8.20
8.20
4.42
4.42
4.42
4.42
4.42
4.42

0
0
4.42
0
0
0
4.42
4.42
SONIC GENERATOR
INTENSITY
db
0
164
164
166
165
0
165
164
0
164

c
0
161
0
162
0
164
165
POWER
KILOWATTS

3.25
2.90
2.90
3.60

3.00
3.20

3.10

3.20

3.00

3.30

3.20
3.50
•   Fan power based on motor-fan combined efficiency of fifty-five  percent.
b   Runs 15 and 17 were to determine mass efficiency by size of sampling cyclone only.
c   Microphone broken - sound Intensity unknown.

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        The high pressure drop across  the  sonic  chamber  during  tests  one
through four was caused by an inlet manifold with  a very small  opening.
Although this tortuous configuration may have  increased  the dust-spray  inter-
actions, the high shear forces encountered may actually  break up  any
agglomerates entering the system.  The  inlet restriction also was  an  added
burden on the fan capacity and was replaced by the normal  inlet before  test
five.
        The increase in volume flow starting with  test eight reflects the
installation and use of gas burners at  the air intake.   This was  required to
keep the temperature in the system high enough to  prevent  the condensation of
the steam as soon as it was introduced.  Runs  12 and 16  were at a  low flow
rate (2000 cfm) while 13 and 14 were at the highest flow rate the  system
could achieve (8000 cfm).
        The fan power required at the  indicated volume and static  pressure
was based upon an assumed motor-fan combined efficiency  of 55 percent.  The
sound intensity and power demands of the sonic generator were taken from
direct readings on the control panel of the Braxton device.  The steam and
water consumptions were determined by Braxton  personnel with calibrated flow
meters.
    B.  EFFECT OF THE SONIC AGGLOKERATOR ON PARTICULATE COLLECTION
        Table 2 summarizes the inlet and outlet dust loading.   The relatively
large portion of the inlet dust that was captured by the cyclone indicates a
fairly coarse particulate.  While this was expected to be the case with fly
ash it was unexpected for the cupola dust because laboratory dispersion tests
with a relatively high ejector air pressure (90 psi) had shown a mass median
diameter of just larger than one micrometer (Appendix D)•  The Braxton dust
feed system was designed to have a similar air pressure  to resuspend the
dust, but the high pressure compressor was out of service during the early
part of the tests.   Therefore, the low pressure compressor at Braxton had to
be utilized and the resulting air pressure (20 psi) to the air ejector prob-
ably failed to break up the agglomerates in the bulk dust and led to a
coarser particulate than obtained in the laboratory.   The high pressure
                                      13

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TABLE 2. P INLET AND OUTLET DUST LOADING, CYCLONE CATCH, CYCLONE UNDERSIZE DUST AND  OVERALL SYSTEM COLLECTION OF ALL PARTICLE SIZES.


RUN
NO.


1
2
3
4
5
6
7
8
9
10
12
13
14
16
18
19
INLET

A

CONCENTRATION
g/03
1 . 3309
1.5859
1.8343
2.2744
1.1202
1.1982
1.6875
1.2012
0.8792
1.5213
0.9227
2.5218
2.0105
2.5690
6.0677
5.4163
B

CYCLONE
FRACTION
.836
.809
.906
.869
.887
.794
.850
.902
.875
.886
.698
.931
.942
.983
.951
.965
C

FILTER
FRACTION
.164
.191
.094
.131
.113
.206
.150
.098
.125
.114
.302
.069
.058
.017
.049
.035
OUTLET

D

CONCENTRATION
g/m3
0.7707
0.1945
0.2629
0.3121
0.2124
0.3806
0.4639
0.1648
0.1499
0.2352
0.5824
1.0376
0.1856
0.2799
0.3936
0.4069
E

CYCLONE
FRACTION
.657
.368
.756
.568
.626
.569
.713
.391
.472
.507
.702
.756
.723
.899
.879
.922

F

FILTER
FRACTION
.343
.632
.244
.432
.374
.431
.287
.609
.528
.493
.298
.244
.277
.101
.121
.078
REDUCTION IN MASS
flF PTH7 PARTTf"7.FQ
Ur Fine rAni il if* a ,
PERCENT

(A C)-(D F)
J-T* X IUU
A C
-20.9
59.4
62.8
54.9
37.0
33.6
47.2
14.6
28.1
33.0
37.8
-45.8
55.3
34.0
84.0
83.2
REDUCTION OF
TflTAT MAQQ
1V1AL nfua 1
PERCENT

*r* l°°
A
42.1
87.7
85.7
86.3
81.0
68.2
72.5
86.3
83.0
84.5
36.9
58.9
90.8
89.1
93.5
92.5

SYSTEM EFFICIENCY
IF FOLLOWED BY
CYCLONE , PERCENT

A"(DAD E) " I0°
80.1
92.3
96.5
94.1
92.9
86.3
92.1
91.6
91.0
92.4
81.2
90.0
97.4
98.9
99.2
99.4

-------
 compressor  became  available  later  in  the  program but  it was  decided  that  a
 change  in operating  parameters  part way  through  the  tests would  be unwise
 so the  low  pressure  air  supply  was utilized  throughout.
         In  addition  to the mass concentration, the cyclone fraction  and the
 filter  fraction  at the inlet and outlet,  Table 2, shows the  percent  reduction
 of total mass  and  the percent reduction of fine  particles.   The  reduction of
 total mass  is  that portion of the  dust that was  removed in the sonic chamber
 by wash out, settling, precipitation, impaction  or whatever  other mechanisms
 may be  involved.   It is  a measure  of  the  AVP as  a dust collector rather than
 a  conditioner.   An average of 86 percent  of the  cupola dust  and  97 percent
 of the  fly  ash is  cyclone collectable before treatment by the AVP so it is
 important to examine the reduction in mass of fine particles.  This  is merely
 the percent reduction of the  cyclone undersize dust at the outlet of the  AVP
 as compared to that  of the cyclone undersize dust at  the inlet.
         Also computed in Table  2 is the system collection efficiency if it
were followed by a cyclone displaying the same collection efficiency as the
 cyclones  in the  sampling trains.  This takes into account both the dust lost
 in the  sound chamber and the  increased collectability of the effluent as  a
result  of the reduction of small particles.  It  is important to keep in mind
when using  the efficiencies shown that the inlet cyclone fraction shown in
 column  B would be  the system  efficiencies without any conditioning whatso-
ever.
        Two tests  (1 and 13) were run in which no sound, steam or water were
used to determine what effect the physical configuration of the Braxton sys-
 tem has on the test aerosol.   It is interesting  to note that under those con-
ditions  the system retains about half of the total dust entering it but the
dust that penetrates the chamber has  a substantially higher portion of its
mass in the cyclone undersize range.   This shows  up as a negative number in
the reduction in mass of fine particles.   This would indicate that the
physical configuration works against  agglomeration by breaking up aggregates
that enter.
        Test six was  run with water spray but no  sound or  steam.   This shows
the positive contribution of the sprays  both  in increasing the percent of  the

                                     15

-------
dust retained in  the chamber  and also in decreasing the fraction of fine
material.  The positive  influence of the water sprays can also be seen by
examining tests two, three and four.  The average reduction in the percent
of cyclone undersize dust is  considerably greater (59 percent versus 37 per-
cent) than those  tests run with the same test dust with sound but with half
the water spray volume (tests 5, 7, 8, 10 and 14).  Figure 2 shows the percent
reduction in the  mass of fine particles as a function of water flow rate
disregarding other system parameters.  Although the data show considerable
scatter, there is a trend toward more efficient reduction of fines at in-
creased water flow rates.  The correlation coefficient of the 13 pairs that
showed a positive reduction in fine particles is 0.43, while the correlation
coefficient of the data  for all tests, including negative reduction in fines,
is 0.65.  The former correlation coefficient is not statistically significant
while the latter  is statistically significant (a = .05).
        Test nine was run with steam and water but no sound to compare the
results with test six without steam or sound.  The steam appears to sub-
stantially increase the percent mass retained in the chamber but has a slight
negative influence on the reduction of fine particles.  Figure 3 shows the
percent reduction in the mass of fine particles as a function of steam flow
rate disregarding other  system parameters.  Disregarding the two tests that
resulted in negative fine particle reduction, the correlation coefficient is
- 0.30.  The correlation coefficient of the data for all runs, including
those with negative reduction in fines, is 0.06.   Neither coefficient is
statistically significant.
        Tests 16, 18 and 19 were run with fly ash and the larger particle
size distribution of this test dust is obvious.  Test 19 was a repeat of
test 18 because of difficulties experienced during test 18.   The data are
included for completeness but are in doubt because the outlet sampling train
nozzle was misaligned during part of the test run.  The strong influence of
the water sprays  can also be seen by comparing the reduction of fine particles
in run 16 (34 percent) without water but with steam and sound versus run 19
(83 percent) with water,  steam and sound.  This is in spite of the fact that
run 16 was at a low flow rate so the residence time in the chamber was about
two and one half  times as long as for run 19.

                                     16

-------
   9O
   eo
    70
S 6°
o
OC.
UJ
0- SO
o

F 40
OC
UJ 30
fe 20
<   10
2   0

O




8  -10

Q
           O


           Q
                                                          O


                                                          O


                                                          O
                                    O
O

a
   -20
  -30
                                             o = CUPOLA DUST


                                             Q - FLY ASH
    0 -
  -50
           O

           I
           01     2345678


                   WATER FLOW RATE, m3/s x I05




        Figure 2.  Effect of Water Flow Rate on the  Reduction

                   of Fine Particles.
                               17

-------
»-

UJ
UJ
CL


in
UJ
    90
    80
    70
    60
    SO
I<°
*
. .   30
U.   20
O
O  -10

o
UJ
tr.  -20
   -30 -





   -40 -




   -5O
           O

           o

           o
           o
           o
           o
           I
                                o = CUPOLA OUST


                                o s FLY ASH
           0     2    4     6    B     10    12

            STEAM FLOW RATE, m3/s x I05
                                                14
 Figure 3.
           Effect of Steam Flow Rate on the Reduction

           of Fine Particles.
                     18

-------
         The  influence  of  the  sonic  generator  can be seen by comparing  test
 6  (water,  no sound,  no steam) with  tests  5  and  7 (water, sound,  no  steam).
 The  addition of  sound  increased  the reduction of fine  particles  and increased
 the  amount of dust retained in the  chamber.   The use of  sound, however,  did
 not  appear to play as  significant a role  in the depletion of small  particles
 as the  addition  of water.  Test  6,  in which water was  added but  no  steam and
 no sound was used, showed  a 33.6 percent  reduction  in  fines.  The use  of
 sound and  water  in tests 5 and 7 averaged 42.3  percent reduction in fines.
 Tests 2, 3 and 4 were  run  with sound and  twice  the  water rate as tests 5 and
 7 and showed a 59.2  percent reduction in  fines.   Figure  4 shows  the percent
 reduction  in the mass  of fine particles as  a  function  of the sonic  generator
 power consumption disregarding other system parameters.   For the 13  tests
 that showed  a positive influence on the fines reduction  the  correlation  coef-
 ficient is 0.33, while the correlation coefficient  of  the data for  all tests
 is 0.68.   The  former coefficient is not statistically  significant and the
 latter is  statistically significant.
        Since most of  the  tests were run with cupola dust, a more detailed
 statistical  analysis was undertaken for those 13  tests.  A multiple regression
 analysis was used  on the  data of the cupola dust tests and showed  the
 following  relationship:
             % reduction in mass of  fine particles = -15.1 + 6.5
             (water flow, m /s x 10  j + 8.3  (sonic generator power,  kilowatts)
An analysis  of variance shows that the regression is highly significant  (99
percent).  It should be noted that the first member on the right side of the
equation is  negative and thus shows  the detrimental influence on fine par-
 ticle reduction  of the physical configuration of the unit as was demonstrated
when tests were run with no sound, water or steam.  Furthermore,  steam con-
sumption does not appear in the relationship because it does not contribute
significantly to the regression.   The model also shows  that the use  of the
sonic generator has somewhat less influence on fine particle reduction than
does the use  of water sprays,  although the interaction  of both plays a  sig-
nificant role
                                      19

-------
   90
   80
   TO
   GO
   50
   40
UJ
Q.
V)
UJ
O  20
h-


2
    10
Ul
z
tt.

en
CO
   -10
O -20

§


S -30
QC
  -40
  -50
           O


           O
                                                 O

                                                 o
                                                 O   O
                                                 o = CUPOLA DUST

                                                 a = FLY ASH
           0           I            2           3.4


          SONIC GENERATOR  POWER  CONSUMPTION, KILOWATTS



      Figure 4.  Effect of Sonic Generator Power Consumption

                 on Reduction of Fine Particles.
                               20

-------
                                                   3                       3
         Increasing  the volume  flow rate  from 2.2 m /s  (5,000 cfm)  to 3.7  m /s
 (8,000 cfm)  and  hence decreasing  the  residence time in the chamber did  not
 seem to adversely affect the performance of the AVP system when run with  steam,
 water and  sound.    Run 14 was  at  the  elevated flow rate with steam, water and
 sound and  the  reduction in the mass of  fine particles  was  55.3  percent.   How-
 ever, the  elevated  flow rate in test  13  when the system was run dry (no water,
 no steam,  no sound)  increased  the  mass of fine particles by 45  percent  which
 indicates  the  breakup of agglomerates that enter the chamber.
         Two  tests were run at  0.82 m  /s  (2,000 cfm)  and again the  effect  of
 residence  time is obscure.  Tests  12  and 16 were run at the reduced flow  with
 steam and  sound  and  the average reduction of fines was 35.9 percent.  This
 indicates  that the  increased residence time with sound and steam is about as
 effective  in reducing the fine particles as running with water  only at  a
 residence  time of two and one  half times less (test 6).  In fact,  running the
 system at  a  high flow rate  with sound, steam and water (test 14) produced
 considerably better  results than running at a low flow rate with sound  and
 steam (tests 12  and  16).

     C.   EFFECT OF THE  SONIC AGGLOMERATOR ON THE  SIZE OF SMALL PARTICLES
         In addition  to examining the  change in the mass  of the  small  particles,
 it  is  of interest to  investigate what changes,  if  any,  are made  in the  size
 distribution of  the  cyclone undersize material.  Effective agglomeration  would
 be  expected  not only  to  decrease the mass  of  the  small  particles that penetrate
 the  cyclone  but also  to  increase the  particle  size of  that portion that
 remains  cyclone undersize at the outlet  of  the AVP.
         Six  stage Andersen  cascade  impactors were  used  downstream  of the  cyclone
 in both  the  inlet and  outlet sampling trains,  except for tests one  and  three
when only outlet impactor samples were taken.  Table 3  compares the concentra-
tion of cyclone undersize dust  as  measured with the glass fiber  high volume fil-
ter and with  Andersen impactors.  The  particle size distributions determined  by
the impactors are shown graphically in Figures 5 through 21 and  in tabular
form in Appendix C.   Figures 18 and 20,  corresponding to tests 15 and 17,
show the particle size distribution upstream and downstream of the  sampling
                                     21

-------
   Table 3.   COMPARATIVE CONCENTRATION MEASUREMENTS OF
              CYCLONE UNDERSIZE DUST WITH GLASS FIBER
              FILTERS AND ANDERSEN IMPACTORS

RUN NO.
lb
2a, b
3b
4a
5b
6
7
8
9
10
12
13
14
16
18
INLET
FILTER,
g/m3
0.22
0.30
0.17
0.30
0.13
0.25
0.25
0.12
0.11
0.17
0.28
0.17
0.12
0.04
0.30
CASCADE
IMPACTOR,
g/m3
_
0.23
-
0.24
0.11
0.20
0.17
0.04
0.06
0.14
0.20
0.16
0.05
0.04
0.18
OUTLET
FILTER,
g/m3
0.26
0.12
0.06
0.14
0.08
0.16
0.13
0.10
0.08
0.12
0.17
0.25
0.05
0.03
0.05
CASCADE
IMPACTOR,
g/m3
0.79
0.29
0.06
0.06
0.05
0.13
0.11
0.07
0.05
0.06
0.14
0.22
0.04
0.02
0.03
denotes different sampling periods for impactor and filter at inlet

denotes different sampling periods for impactor and filter at outlet
                               22

-------
          10-
          9-
          8-
           7-
           6 •

           3-
t-l
01
to
Q
0)
r-l
O
             9
             6
             7
             6

             5
                                                                                         X  Outlet
              0.01
                                                                                         98  99
                                                                                                      99.9
                            Figure 5.
                                          5    >0    2O   SO  40  SO  60  70   30     90   05
                                        Percent Mass   ^  Stated  Particle Diameter
                                          Particle Size Distribution     of  Cyclone Undersize Dust  for  Test 1

-------
       10-

       9-

       8-

       7-


       6 •


       5-
0)
S
CO
••-I
a)
u
••-I
CO
PM
                                                                                      D   Inlet
                                                                                      :    i
                                                                                      X   Outlet
          001
                   O.I
                                           10
                                                DO  30  4O  50 60  70
                                                                      30
                                                                            90
                                                                                      93   99
                                                                                                   S9.9
                                                                                                          90.D9
                                    Percent Mass  ^ Stated Particle Diameter

                         Figure 6.  Particle Size  Distribution(s)  of Cyclone  Undersize Dust  for Test 2

-------
Ln
     0)
     AJ
CO
•i-l
P

0)
t-H
o
           10-

           9-

           8-


           7 -


           6 •



           5-
              9


              B


              7



              6



              3
                                                                                          X  Outlet
               0.01       0.1         123     10    ZO   JO  40  30  CO  70   00     90   93    93  99        39.9


                                              Percent Mass  ^  Stated Particle  Diameter


                         Figure  7.   Particle Size Distribution(s)  of Cyclone Undersize  Dust for  Test  3
                                                                                                           99.99

-------
t-l

-------
e
I
Q
4J
M
       10-
       9-
       8-
       7-
       6 •

       5-
9
B
7
6

3
           0.01
                                           z
                                                                    0   Inlet
                                                                    X   Outlet
                    0.1
                                           10
                               20  SO  40  SO 60  70   SO     9O   95    98  99
                             Percent  Mass ^   Stated Particle Diameter

Figure 9.    Particle Size  Distribution(s) of Cyclone Undersize Dust for Test  5
                                                                                                   99.9
                                                                                                         99.99

-------
1-0
CO
l-i
HI
4-1
0)
s
n)
•1-1
Q
     u
    •1-1
                                                                                           0  Inlet

                                                                                           X  Outlet
              0.01
                                           10    20   JO  40   SO  60  70   80    90   95


                                      Percent  Mass  ^   Stated Particle Diameter
                                                                                           98  99
                                                                                                        99.9
                                                                                                               99.99
                    Figure 10.     Particle  Size Distribution(s) of  Cyclone Undersize Dust  for Test  6

-------
VO
    0)
    4-1
p


-------
u>
o
    0)
    e
    to
    o
    .,-<

    4-1
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    P-i
          10-


          9-


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          6



          5-
9-


8-


7



6




S
              O.OI
                                                         ^
                                                                                             d   Inlet
                                                                                              I

                                                                                          i   X   Outlet
                      O.I
                                         5    10     ZO   50  40  SO 60  70   8O    90   99


                                            Percent  Mass / Stated Particle  Diameter
                                                                                          98   99
                                                                                                        99.9
                                                                                                              99.99
                  Figure  12.   Particle  Size Distribution(s) of  Cyclone Undersize Dust  for Test 8

-------
a
0)
4-1

S
CO
•1-1
Q
J-i
cfl
     10-

     9-

      8-


      7-


      6



      5-
                                 JL
                                                                                      0   Inlet


                                                                                      X   Outlet
         0.01
                  O.I
I    10    20   JO  4O   SO  60  70  80    90   99


  Percent Mass  ^  Stated Particle Diameter
                                                                                     98  99
                                                                                                        99.99
             Figure 13.    Particle Size Distribution(s)  of Cyclone Undersize Dust  for  Test 9

-------
N>
   0)
   a
   CO
   0)
   r-<
   u
          10-

          9-

          8-

          7-


          6 •


           3-
9-

8-

7


6


3
                                                                                         0    Inlet


                                                                                         X    Outlet
              0.01
                      O.I
                                              10
                                                    20   30  40  50  60  70
                                                                          90
                                                                               90
                                                                                    93
                                                                                         98  99
                                                                                                       99.9
                  Figure 14.
                         Percent Mass  ^   Stated  Particle Diameter


                    Particle Size Distribution(s)  of Cyclone Undersize Dust  for Test 10

-------
    e
CO   4J
Co   QJ
    a
    o

    0)
    i-i
    o
    •H
          10-


          9-


          8-


          7-



          6



          S-
                                               	
                                                                                          ,0
                                                                 Inlet
                                                                                               Outlet
              o.oi
                      O.I
                                              10
                                                        SO  40  SO 6O  7O
                                                                          80
                                                                                90
                                                                                     95
                                                                                          98   99
                                                                                                       9<».9
                                                                                                              99.99
                 Figure  15,
          Percent Mass ^   Stated Particle Diameter

Particle  Size Distribution(s) of Cyclone Undersize Dust  for  Test 12

-------
   0)
   4-1
   CO
   •H
   Q

   OJ
   i-l
   o
U)  -H
4>  -U
   Vi
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            10-

            9-

            8-

             7-

             6


             5-
                                                                                             ;0  ; Inlet
• X   Outlet
                0.01
                         O.I
                                                                                             90
                                                                                                99
                                                                                                          99.9
                                                                                                                 99.99
                                   12     5     10    20   30  40  JO  60  70   00     9O   S3

                                               Percent Mass^ Stated Particle Diameter

                               Figure 16.  Particle Size Distribution(s) of Cyclone Undersize Dust for  Test 13

-------
OJ

Ul
.2
o


-------
    10-

    9-

    8-

     7-

     6


     5-


                                                                                    0    Before Cyclone

                                                                                    X    After Cyclone

-------
U)
    I
    •1-1
        10-
        9-
        8-
        7 -
        6 •

        3-
9
8
                                        X
                                             X
                                                                                       I  0 i   Inlet
                                                                                       i
                                                                                         X ;   Outlet
            0.01
                     O.I
                                                                                  93
                                                                                       58  99
                                                                                                    99.9
                    12     S    10    CO  30  40  SO 6O  70   80     90
                         Percent Mass  ^ Stated Particle Diameter
             Figure  19.   Particle Size Distribution(s) of Cyclone  Undersize Dust  for Test 16
                                                                                                           90.99

-------
00
    
-------
    M
    01
    4J

IjO   £!
vo   n}

    b

    o>
    t-i
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    M
    (0
        10-

         9-

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         6


         5-
             0.01
y
0   Inlet


X   Outlet
                     0.1
                                             lO
                                                   20
                                                       JO  «O  SO  60  TO
                                                                         80
                                                                               90
                                                                                   99
                                                                                         98   99
                                                                                                      99.9
                                                                                                            99.99
                                            Percent Mass  -^  Stated  Particle Diameter

                  Figure  21.   Particle  Size Distribution(s) of  Cyclone Undersize Dust for  Test 18

-------
cyclone with flyash and  cupola dust, and served as the field calibration of
the collection efficiency by particle size of the cyclone collectors as
shown in Appendix  B.
        The particle  size distributions of the cyclone undersize dust at the
inlet and outlet show no clear trend.  More often than not there is a signif-
icant shift in the size  distribution but not in any consistant direction.
For example, tests 2  and 4 were run at nearly identical conditions but the
results showed opposite  effects.  Test 2 resulted in a substantially larger
size at the outlet but test 4 resulted in a somewhat smaller size at the
outlet.  Tests 5,  6 and  7, on the other hand, resulted in practically no
change between the inlet and outlet particle diameters but test 5 and 7 were
run with sound and test  6 was run without sound.
        A comparison  of  tests 8 and 9, however, indicates a positive influ-
ence of sound because of the larger size of the outlet cyclone undersize dust
in test 8 with sound  as  compared to no change in test 9 without sound.
        The lack of any  clear trend of a change in the particle size of the
cyclone undersize dust after going through the sonic agglomerator is also
indicated in Figure 22.  This is a plot of the mass median diameter of the
fine particles at the inlet versus that at the outlet.  Each point is numbered
according to the test number in order to facilitate identifying each one with
the system operating  parameters in Table 1.  As can be seen on Figure 22,
test 2 resulted in the greatest increase in mass median diameter of the outlet
dust.  The reason  for this is not understood and a repeat test at the same
conditions (test 4) failed to demonstrate any increase in the outlet mass
median diameter at all.
   D.  ESTIMATE OF OPERATING COSTS
       An estimate of the operating costs was made for the Braxton sonic
agglomerator.  The operating parameters such as steam and water consumption
and electrical requirements for each run were expanded to a 16.67 m /s
       3
(1000 m /min or 35,000 cfm) system by a simple multiplier.  For example, if
                                                        3
the system required 15 kilowatts at a flow rate of 2.2 m /s then 7.58 times
15 kilowatts, or 113.64  kilowatts, would be required for the scaled up unit.
The same type of scaling was done for steam and water consumption and the

                                     40

-------
   3.0
   2.8
    2.6
    2.4


Z
a.
 -   2.2
o

g   2.0
o
    1.8
o

3   '••
O
O

«   I 9
ijl   I.C

UJ



5   1-0
en
CA
4
    0.8
   0.6
   04
   0.2
                   I
                                 °2
                           09
                            O
                             IO
O_
                                 I
                                        I
                                                   O

                                                   13  O
                                                        12
                                                    16
                                                          '14
                                              NUMBER DENOTES TEST
                                              I
                                                     I
      0     0.2    0.4    0.6     0.8     10     1.2     1.4     L6     1.8


         MASS MEDIAN DIAMETER DOWNSTREAM OF INLET CYCLONE, JOM



      Figure 22.  Effect of AVP System on Mass Median Diameters

                   of Cyclone Undersize Dust.
                                                                        2.0
                                     41

-------
cost for each parameter estimated for each test run in Table 4.  An estimated
annual operating cost based upon 8,000 hours operation is also included.
       The estimated cost for steam consumption is based on a purchased
price of $3.10 per 1,000 pounds.  Water costs are based on $0.40 per 100
cubic feet and the electricity rates used are $0.025 per kilowatt hour.
       It should be pointed out that the cost estimates in Table 4 do not
include the additional power requirements for a high efficiency cyclone.
Some of the earlier performance data were based on the use of the cyclone
in the sampling train and the operating cost of a scaled up cyclone are not
reflected in the cost estimates.
        Test 7 reflects normal water and power consumption while test 8 shows
the same conditions except for steam addition.  The estimated annual operating
cost under the conditions in test 7 is $ 13.30/m3/minute ($0.38/cfm) and for
test 8 it is $46.22/m3/minute ($1.32/cfm).   These estimates are based  upon
the previously explained conditions and costs but do not include any annual-
ized capital costs.
        It is clear that within the limitations of the assumptions and con-
ditions associated with Table 4 that by far the most expensive item is steam.
The effectiveness of steam addition is at best questionable and more than
likely detrimental so it is safe to assume that the costs associated with
steam use could be subtracted out.
                                     42

-------
            Table 4.  ESTIMATED OPERATING COSTS OF AVP SYSTEM0
Test
1
2
3
4
5
6
7
8
9
10
12
13
14
16
18
19
Cost per 1000 m3 of Gas Treated, Dollars
Steam
0
0
0
0
0
0
0
0.0688
0.0688
0.3440
0.0688
0
0.0688
0.2339
0.0688
0.0688
c
Water
0
0.0056
0.0056
0.0056
0.0028
0.0028
0.0028
0.0028
0.0028
0.0028
0
0
0.0028
0
0.0028
0.0028
d
Electricity
0.0391
0.0494
0.0484
0.0484
0.0270
0.0155
0.0249
0.0247
0.0155
0.0243
0.0290
0.0361
0.0418
0.0299
0.0246
0.0254
Annual Cost,
Dollars6
18,771
26,400
25,920
25,920
14,304
8,784
13,296
46,224
41,808
178,128
46,944
17,328
54,432
126,624
46,176
46,560
abased on a 1000 m /min (35,000 cfm) system


 based on $3.10 per 1000 pounds


°based on $0.40 per 100 ft.3


 based on $0.025 per kilowatt hour

Q
 based on 8000 hours of operation per year
                                  43

-------
                                 APPENDIX A
          ACOUSTIC COAGULATION AND THE BRAXTON SONIC AGGLOMERATOR

    Mednikov  (1965)  gave  a  much more advanced presentation on this subject
than did Fuchs  (1964)  or  Green and Lane  (1964), and his results are applied
here to the Braxton  acoustic agglomerator .  It is Mednikov's conclusion that
for industrial  gas cleaning situations,  the predominant mechanism of acousti-
cal agglomeration  is the  different vibratory velocities and phases of par-
ticles of different  sizes,  despite the great variety of possible mechanisms
presented in  the literature.
    Coagulation is generally governed by the following equation:

                                           2
                                dn/dt =-K n
where
        t = time, sec
        n = concentration,  cm
                                    2
        K = coagulation constant, cm  x cm/sec.
    The units for K  suggest the general mechanism: particles in motion "sweep"
a given volume  per unit time, the product of their effective cross sectional
area and their  velocity,  and the number of particles is decreased by each
effective particle-particle collision in this swept volume.
    The aerodynamic diameter of a particle, or equivalently its "relaxation"
time t, governs the  particle's response to velocity changes of the medium in
which it is suspended.  The ratio of particle velocity amplitude Up to gas
velocity amplitude Ug  in  a sonic field is (Fuchs,  1964; Mednikov,  1965):
where
                       Up/Ug =!/[! + (2*)2 (t/t )2]^
                                                 s
                    2
        T  =  Cp  d  /18 |a, the particle relaxation time, sec,
        t  =  1/f, the vibration period of the sound, sec,
         S
        f  =  sound frequency, sec   or Hz
                                      44

-------
        d   =  particle  diameter,  cm,
         P                          3
        p   =  particle  density, g/cm ,
         \JL  =  medium viscosity, poise
 Roughly, this means that  small particles,  those  having  2ntf  « 1,  follow
 the gas vibrations, and  large particles,  those having 2nTf » 1, do not
 vibrate appreciably.   At  the  frequency  of  the Braxton device,  ~ 400 Hz,
 the critical  T  is
               c
                              T   =  l/2*f
                               c
                                            -4
                              T   =  4.0  x  10  sec
                               c
 which  is the  relaxation  time of  a 12-^m diameter particle of unit  density.
 Particles of  T « T  will agglomerate on particles of T » T ,  if  they
 agglomerate at all.  Since it takes many "small" particles to  change  the
 mass of a "large" particle, the primary change in the size distribution
 would  be a decrease in the number (and  mass) concentrations  for particles
 having T « T and  an  increase for particles having T » T ,  reflected by:
        (a) a  decrease in the total number  concentration,
        (b) an increase in the number mean  and median diameters,
        (c) no change  in  the mass mean  diameter,
        (d) an increase in the mass median  diameter,
        (e) a  decrease in the geometric standard deviation (if
            a  log-normal curve is fit).
 Of all these  effects,  the most noticeable should be the change in  the
 "small" particle concentration, here (Braxton) the respirable  fraction.
 This may be the most useful test of whether or not the device is ag-
 glomerating particles.
    Mednikov's model subdivides the aerosol into its small particle con-
 centration n^  and its  large particle concentration n  (assumed to be
 constant with  time).  The coagulation equation for the aerosol becomes:
where
                       dn/dt = dn2/dt = - Kfll
        n = n  + n_
                                         3
        K   = coagulation coefficient, cm /sec,
         3 J.
                                    45

-------
and
where
         Kal  -° (*rl    V'
            2
         jtr,   is  an average cross-sectional area  for  the  large particles
 and  0(x)  means "of the  order  of magnitude of x."
     The  coagulation equation  here  becomes

                              n2 "  (lVo 6XP (" Kal nl C)
 and  the  exponential time  dependence has been found in many experiments
 (Mednikov,  1965).   Assuming n_ »  n  ,  then n = n« and n  = (n^) .

     Coagulation  is appreciable, n/n  « 1, if

                              Q = ni ri2 V >> L-
 The  gas  velocity amplitude is given by
                                           1/2
                            U8  =  (2j/pg V
where
                                    2        -7     2
         J =  sound  intensity, erg/cm -sec, 10   W/cm  ,
                              2
        p  =  gas  density,  g/cm  ,
         O
        c  =  gas  speed  of  sound, cm/sec,
        U  =  gas  vibration velocity amplitude, cm/sec.
         o
Coagulation will  thus be improved by increasing
                                 2    1/2 ^
                            nn r.,   J    t
                              1   1         res
in the coagulation chamber: t   is the residence time.  Note the rela-
                              res                  1/2
tively weak dependence  upon power level changes, J

    The Braxton device  has a  5 hp acoustic power source radiating into a
3-foot diameter cylinder which is about 10 feet long.  This gives a gas
velocity amplitude:
                                    46

-------
           2x5 hp x 746 watts/hp x  10   erg/watt	


       1.2x10   g/cm  x 3.3x10  cm/sec  x  6.3x10   cm
                                                       1/2
                                                         2
                                                 = 5.4x10  cm/sec
If  the large particle concentration  is  due  to  the  Braxton water  spray


nozzles, then that concentration  is



                          n.  = m/(4n/3)p  r3 V
                            i            w
where
         m = mass flow of water, g/sec


                                 (

                                3
                          3

V = volume flow of air, cm /sec
        p  = water density, g/cm
         w


        ~~3~
        r  = water droplet mass mean diameter, cm.




    The residence time of the particles in  the agglomerator chamber will


be the chamber volume divided by  the flow rate or




                             t    = V /V .
                              res    c



the parameter governing acoustic  coagulation is
                                      2
                           Q = n, JT r,  U  t
                                1    1   g  res



and it will have a V   dependence on flow rate due to its residence time


dependence; if the large particle concentration n1 is due primarily to

                                       •-1
the water spray, as assumed, then n.. <* V   will increase the dependence

                 •-2         --2
of Q on V to Q a V  •  (This V   dependence of coagulation will be some-


what offset by increased large particle deposition at larger V due to im-


paction on walls and in bends and due to coagulation produced in non-


oscillating accelerations of the air flow.)  Since the spray concentra-


tion n  is related to the spray mass flow and mass average spray droplet



        "
  ..   ,x    .
radius (r )    by            _

                               3 •
                       m « n r   V,
                              2        23
                       V    r   « m (r  ITC  ),
                                     47

-------
the coagulation rate will be  increased at constant droplet mass  flow  for
smaller droplets, as long as  they are  large enough so  their  T » T  .

    Whether or not  the  spray  evaporates completely can be estimated.
The effect of a relative velocity (U   - U ) between particle and  fluid
                                    t    O
is to accelerate mass and heat  transfer in comparison  with the rates
appropriate to a stationary particle.  For water droplets evaporating,
this multiplies the stationary mass loss rate by a ventilation factor
(Green and Lane, 1964)  of
                            [1+0.3  (Re )1/2J
where
        ReP = p (UP - V
For a falling 20-(j.m diameter water droplet (U  - U ), U  =1.2 cm/sec
                  _ 2                         P    8    P
and Re  = 1.6 x 10  , so that this ventilation factor is small.  For
      P                 2
acoustical U  = 5.4 x 10  cm/sec, and the Reynolds number becomes 7.3,
            O
so the evaporation rate is increased by about a factor of 1.8.  At 80
percent r.h. and 20 C, a 20-um diameter water droplet has a lifetime of
2.4 sec (Green and Lane, 1964); droplet lifetime is proportional to
droplet area for droplets larger than 1 p.m or so.  The Braxton device
has residence times -^ 1 sec so that the droplets should not have evap-
orated completely before exiting the acoustic chamber.

    An approximate calculation for the Braxton coagulation efficiency
follows:
        V = 5,000 cfm = 200 ft3/sec    ( .       . _
                   „                   > t    = 1.2 sec
        v  = 100 ft3                   !  res
         c
        	                         f    2
        r  = 10 urn spray droplets  = (r.. )
     J = 5 hp
    i~ = 10 un
     m = 1 gal/min of spray
                              3                     2
     m = 4 liters/min = 4 x 10  g/60 sec = 0.66 x 10  g/sec

nl rl2 = m/^ *T Pw
                                     48

-------
                     2
        U  = 5.4 x 10  cm/sec
         g
      .'. Q = 3.14 (2.8 x 10~2 cm"1) (5.4 x  102  cm/sec) (1.2  sec)
         Q = 57
         Q » 1 so n2/(n )  « 1 and  thus  Braxton  device  should  be
         efficient in reducing the  small particles by  droplet-particle
         collision.

(This kind of calculation can only  tell whether n/n  « 1  or  not and
should not be taken as a means for  getting n/n =  exp  (-Q) more  accurately
than to an order of magnitude in Q.   There are many  second-order effects.)

    A somewhat more sophisticated calculation  of the acoustic agglomera-
tion would take into account the tendency  of the sub-micron fraction  of
the aerosol to avoid capture by following  the  streamlines  of  flow around
the larger droplets as the flow oscillates.  This  can  be added to the
model through an efficiency factor  e-multiplying Q,  acknowledging that
the geometric cross-section of the  large particles,  n  r,^, is different
                                                —2
from the effective collision cross-section, e  it r, .   This factor e will
be a function of the aerodynamic diameter  of the small  particles, or
e = e(r»).  Theory and practice indicate that  € «•  1  for T9 U  /r   » 1
       ^                                                   9 £ 1
and e -» 0 for T_ U /r..  « 1.  For r   = 10 \m,  U  = 6  x 10  cm/sec,
T» U /r  = 1 at T- = 1.7 x 10   sec, which corresponds  to  d_  = 2  r_ =
0.7 urn.   Thus we would expect the agglomerator to  be significantly less
efficient for particles smaller than  l/2-(am diameter.
                                     49

-------
                                REFERENCES
Fuchs, N.A. (1964):  Mechanics of Aerosols, Pergamon Press, New York.

Green, H.L. and Lane, W.R. (1964):  Particulate Clouds;  Dusts, Smokes
       and Mists.

Mednikov, E.P (1963):  Translator:  Larrick, C.V., Acoustic Coagulation
       and Precipitation of Aerosols, Consultants Bureau, New York, 1965.
                                    50

-------
                                 APPENDIX B
                      CALIBRATION OF SAMPLING EQUIPMENT
Cyclone Calibration;
    The cyclones were calibrated in the GCA laboratory using a calibrated
orifice to determine the  flow rate.  The pressure drop across the cyclone
was plotted against the flow rate through the orifice on log-log paper and
the line of best fit drawn.  The resulting calibration curves are presented
in Figures B-l through B-4.
Critical Orifice Flow Rate Determination;
    The critical flow rates through the orifices were determined using a
Schutte and Koerting calibrated rotameter.  The measured flow rates corrected
to standard conditions are presented in Table B-l.
                  Table B-l.  Critical Orifice Flow Rates
                  Orifice
Flow Rate at Standard Condi-
       tions, scfm
                     A
                     B
          0.965
          1.060
Cyclone Removal Efficiency by Particle Size
    Field tests 15 and 17 were run to determine the cyclone removal
efficiency by particle size for fly ash and cupola dust.  Andersen impactors
were located upstream and downstream of the sample train cyclone.  The samples
were collected from the inlet sampling port of the Braxton AVP system.
System parameters are presented in Table B-2.
                                      51

-------
   IOO


   9O



   8O



   TO




   6O





   50






   40








   30
fe   M
oc




Q   20
    15
    10
                     I
I
I
I
I
     I                2        3      456789  10



       PRESSURE DROP ACROSS CYCLONE,  INCHES OF WATER








          Figure B-l.  Cyclone #1 Curve
                            52

-------
    IOO

    90

    80

    TO


    6O


    5O



    40



U.
O   30

LJ
b   25
o
    20
    15
    10
                      I
                                      I
                                           I
I
I	I
      I                2         3      456789 10


        PRESSURE  DROP ACROSS CYCLONE, INCHES OF WATER




           Figure  B-2. Cyclone #2  Calibration Curve
                               53

-------
    IOO

    90

    80


    70


    60


    5O




2   40
u_
O


H   30|-
a
    as
    20
    15
    10
                      I
I
I
I   I   I
      I                2        3      456789 10


       PRESSURE  DROP ACROSS CYCLONE, INCHES OF WATER




            Figure B-3.  Cyclone #3 Calibration Curve
                                54

-------
   IOO


   90


   80


   70



   60



   50
2
li_
O
h-   30
^
cr.
    20
    15
    IO
     I                2         3      456789  10



       PRESSURE  DROP ACROSS  CYCLONE, INCHES  OF WATER




           Figure B-4.  Cyclone #4 Calibration Curve
                                55

-------
   Table B-2.  System Parameters During Cyclone Removal Efficiency Tests
TEST #
15
17
DUST TYPE
fly ash
cupola
SYSTEM FLCW,
m3/s
2.5 (5000 cfm)
2.5 (5000 cfm)
CONCENTRATION,
g/m3
2.80 (1.22 gr/ft3)
3.06 (1.34 gr/ft3)
DUST
PRECONDITIONING
none
none
        Results of cyclone removal efficiency measurements for fly ash and
cupola dust are presented in Figures B-5 and B-6.  Difficulties encountered
necessitated combining the mass collected on certain impactor stages.  In the
fly ash test, removal efficiencies were determined for the combined first and
second stage and for the combined fourth, fifth and sixth stages.  Combining
was required for the first and second stage because of reintrainment which
resulted from the collection of too-large a sample.  Combining of stages 4, 5
and six was used to compensate for the clogging of several of the jets which
impact on stage 5.  In the cupola dust test, removal efficiencies were also
calculated for the combined fourth, fifth and sixth stages due to clogging of
the jets which impact on stage 5.
                                      56

-------
    100
    90
    80
                                            		O
Ul
O
£C
UJ
Q.


O
z
UJ
O
UJ
I
UJ
OL
    70
60
50
    40
50
    20
     10
                  I            23456


                              PARTICLE  DIAMETER, \un


              Figure B-5.  Cyclone Removal. Efficiency by Particle  Size of Fly Ash

-------
t_n
00
                100
                90
                80
             S   70
             o
             (T
             UJ
             Q.   60
             O
             o
             UJ
                50
40
                 30
             UJ
             CC   20
                 10
                 0
                                                                               		O
                                               O
                         Figure  B-6.
                         23456

                         PARTICLE DIAMETER, iun

                     Cyclone  Removal Efficiency by Particle Size of  Cupola Dust

-------
                                 APPENDIX C
                       PARTICLE SIZE DISTRIBUTION DATA

    The following table presents the particle size distribution data as
determined by six stage Andersen impactors.  Before use, the collection
surfaces were coated with a thin, uniform layer of petroleum jelly to
minimize particle bounce and reintrainment.
    The aerodynamic particle size cutoff for each stage is based upon an
assumed particle density of 2.0.  Although this value is only an estimate,
any shift in the size cutoff due to a different density would be exactly
the same for both upstream and downstream impactors.
                                     59

-------
                         Table C-l.   PARTICLE SIZE DISTRIBUTION DATA
                         TEST 1
                                           OUTLET

                                  Size Range,  urn
                                      < 0.36
                                  > 0.36 -  < 0.7
                                  > 0.7  -  < 1.4
                                  > 1.4  -  < 2.3
                                  > 2.3  -  < 3.9
                                  > 3.9  -  < 6.5
                                      > 6.5
                         Cumulative  Mass,
                             Percent	
                               0.0
                              17.7
                              40.8
                              56.9
                              57.7
                              75.4
                             100.0
TEST 2
                  INLET

         Size Range, qm
             < 0.36
         > 0.36 - < 0.7
         > 0.7  - < 1.4
         > 1.4  - < 2.3
         > 2.3  - < 3.9
         > 3.9  - < 6.5
             > 6.5
Cumulative Mass,
    Percent	
      0.0
     42.9
     70.1
     70.1
     79.2
     87.0
    100.0
                                           OUTLET
Size Range, urn
Cumulative Mass,
    Percent
Filter
6
5
4
3
2
1
< 0.36
> 0.36 - <
> 0.7 - <
> 1.4 - <
> 2.3 - <
> 3.9 - <
> 6.5

0.7
1.4
2.3
3.9
6.5

0.8
34.2
40.8
46.7
55.8
89.2
100.0

-------
Table C-1 (continued).   PARTICLE SIZE DISTRIBUTION DATA
      TEST 3
TEST 4
Stage
Filter
6
5
4
3
2
1
OUTLET
Cumulative Mass,
Stage Size Range, urn Percent
Filter < 0.36 15.4
6 > 0.36 - < 0.7 48.1
5 > 0.7 - < 1.4 59.6
4 > 1.4 - < 2.3 63.5
3 > 2.3 - < 3.9 67.3
2 > 3.9 - < 6.5 69.2
1 > 6.5 100.0
INLET
Cumulative Mass,
Size Range, urn Percent Stage Size Rai
< 0.36 29.0 Filter < 0
> 0.36 - < 0.7 52.2 6 > 0.36
> 0.7 - < 1.4 68.0 5 > 0.7
> 1.4 - < 2.3 71.3 4 > 1.4
> 2.3 - < 3.9 72.4 3 > 2.3
> 3.9 - < 6.5 72.4 2 > 3.9
> 6.5 100.0 1 > 6
                                                  OUTLET
                                                          Cumulative Mass,
                                                              Percent	
                                                               42.8
                                                               79.5
                                                               91.6
                                                               92.4
                                                               93.5
                                                               93.5
                                                              100.0

-------
                             Table C-l (continued).  PARTICLE SIZE DISTRIBUTION DATA
           TEST  5
M

S tage
Filter
6
5
4
3
2
1
TEST 6

Stage
Filter
6
5
4
3
2
1
INLET
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
INLET
Size Range, um
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6,5

Cumulative Mass,
Percent
21.4
41.9
62.0
67.1
70.7
73.7
100.0

Cumulative Mass,
Percent
20.9
40.2
60.4
67.8
78.8
82.6
100.0
                                                                               OUTLET

                                                                      Size Range, urn
                                                                          < 0.36
                                                                      > 0.36 - < 0.7
                                                                      > 0.7  - < 1.4
                                                                      > 1.4  - < 2.3
                                                                      > 2.3  - < 3.9
                                                                      > 3.9  - < 6.5
                                                                          > 6.5
                                                                               OUTLET

                                                                      Size Range, urn
                                                                          < 0.36
                                                                      > 0.36 - < 0.7
                                                                      > 0.7  - < 1.4
                                                                      > 1.4  - < 2.3
                                                                      > 2.3  - < 3.9
                                                                      > 3.9  - < 6.5
                                                                          > 6.5
Cumulative Mass,
    Percent	
     16.1
     43.9
     71.1
     79.4
     80.5
     81.9
    100.0
Cumulative Mass,
    Percent	
     17.2
     37.0
     62.4
     69.3
     69.5
     70.7
    100.0

-------
                   Table C-l (continued).  PARTICLE SIZE DISTRIBUTION DATA
TEST 7
                  INLET
OUTLET
Stage
Filter
6
5
4
3
2
1
TEST 8
Stage
Filter
6
5
4
3
2
1
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
INLET
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
Cumulative Mass,
Percent
25.6
50.4
68.4
71.8
71.8
71.8
100.0
Cumulative Mass,
Percent
43.6
81.6
95.1
95.1
95.1
95.1
100.0
Stage
Filter
6
5
4
3
2
1
Stage
Filter
6
5
4
3
2
1
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
OUTLET
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 -~< 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
Cumulative Mass,
Percent
18.3
42.0
65.7
72.4
74.6
76.8
100.0
Cumulative Mass,
Percent
6.7
34.7
85.4
85.7
86.1
86.4
100.0

-------
                   Table C-l (continued).   PARTICLE SIZE DISTRIBUTION DATA
TEST 9

Stage
Filter
6
5
4
3
2
1
TEST 10

Stage
Filter
6
5
4
3
2
1

INLET
Size Range, urn
< 0.
> 0.36 -
> 0.7 -
> 1.4 -
> 2.3 -
> 3.9 -
> 6.

36
< 0.7
< 1.4
< 2.3
< 3.9
< 6.5
5
INLET
Size Range, urn
< 0.
> 0.36 -
> 0.7 -
> 1.4 -
> 2.3 -
> 3.9 -
> 6.
36
< 0.7
< 1.4
< 2.3
< 3.9
< 6.5
5

Cumulative Mass,
Percent
27.6
55.1
88.2
88.2
88.2
88.2
100.0

Cumulative Mass,
Percent
18.3
50.6
76.6
78.6
78.6
78.6
100.0
                                                   Filter
                                                     6
                                                     5
                                                     4
                                                     3
                                                     2
                                                     1
                                                                     OUTLET
                                                                             Cumulative  Mass,
                                                            Size Range,  urn       Percent	
    < 0.36
> 0.36 - < 0.7
> 0.7  - < 1.4
> 1.4  - < 2.3
> 2.3  - < 3.9
> 3.9  - < 6.5
    > 6.5
                                                                     OUTLET

                                                            Size Range, urn
                                                                < 0.36
                                                            > 0.36 - < 0.7
                                                            > 0.7  - < 1.4
                                                            > 1.4  - < 2.3
                                                            > 2.3  - < 3.9
                                                            > 3.9  - < 6.5
                                                                > 6.5
 11.4
 27.2
 91.2
 92.1
 94.8
 95.7
100.0
                 Cumulative Mass,
                     Percent	
                      10.2
                      40.7
                      81.0
                      86.9
                      86.9
                      86.9
                     100.0

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                   Table C-l (continued).  PARTICLE SIZE DISTRIBUTION DATA
TEST 12
                  INLET
OUTLET
Stage
Filter
6
5
4
3
2
1
TEST 13
Stage
Filter
6
5
4
3
2
1
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
INLET
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
Cumulative Mass,
Percent
10.7
27.5
48.9
55.2
57.2
58.8
100.0
Cumulative Mass,
Percent
4.1
16.9
51.1
57.2
60.3
63.2
100.0
Stage
Filter
6
5
4
3
2
1
Stage
Filter
6
5
4
3
2
1
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
OUTLET
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
Cumulative Mass,
Percent
3.1
14.0
47.0
69.3
71.5
71.9
100.0
Cumulative Mass,
Percent
1.6
17.2
39.2
51.8
54.4
56.3
100.0

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                   Table C-1 (continued).   PARTICLE SIZE DISTRIBUTION DATA
TEST 14

Stage
Filter
6
5
4
3
2
1
TEST 15
Stage
Filter
6
5
4
3
2
1
INLET
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5

Cumulative Mass,
Percent
4.6
20.1
53.6
70.6
81.4
86.6
100.0
BEFORE CYCLONE
Size Range, urn
< 0.36
> 0.36 - < 0.7
> 0.7 - <.1..4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
Cumulative Mass,
Percent
0.0
1.4
3.6
6.5
13.5
53.5
100.0
                                                                     OUTLET
                                                                             Cumulative Mass,
                                                            Size Range,  qm       Percent	
                                                                < 0.36             0.0
                                                            > 0.36 - < 0.7        18.6
                                                            > 0.7  - < 1.4        69.2
                                                            > 1.4 .- < 2.3        85.5
                                                            >2.3  -<3.9        88.4
                                                            > 3.9  - < 6.5        88.4
                                                                > 6.5            100.0
                                                                 AFTER CYCLONE
                                                                             Cumulative Mass,
                                                            Size Range, urn       Percent	
                                                                < 0.36
                                                            > 0.36 - < 0.7
                                                            > 0.7  - < 1.4
                                                            > 1.4  - < 2.3
                                                            > 2.3  - < 3.9
                                                            > 3.9  - < 6.5
                                                                > 6.5
  1.2
 17.2
 59.3
 66.0
 68.6
 70.9
100.0

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                   Table C-1 (continued).   PARTICLE SIZE DISTRIBUTION DATA
TEST 16

Stage
Filter
6
5
4
3
2
1
TEST 17
S tage
Filter
6
5
4
3
2
1
INLET
Size Range, pun
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5

Cumulative Mass,
Percent
4.4
24.4
62.9
79.2
85.9
89.6
100.0
BEFORE CYCLONE
Size Range, um
< 0.36
> 0.36 - < 0.7
> 0.7 - < 1.4
> 1.4 - < 2.3
> 2.3 - < 3.9
> 3.9 - < 6.5
> 6.5
Cumulative Mass,
Percent
0.0
3.7
8.0
12.0
15.0
25.3
100.0
                                                                     OUTLET
                                                                             Cumulative  Mass,
                                                            Size Range,  qm       Percent	
                                                                < 0.36             0.0
                                                            > 0.36 -  < 0.7        28.1
                                                            > 0.7  -  < 1.4        65.6
                                                            > 1.4  -  < 2.3        71.9
                                                            > 2.3  -  < 3.9        71.9
                                                            > 3.9  -  < 6.5        73.5
                                                                > 6.5            100.0
                                                                 AFTER CYCLONE
                                                                             Cumulative Mass,
                                                            Size Range, um       Percent	
                                                                < 0.36
                                                            > 0.36 - < 0.7
                                                            > 0.7  - < 1.4
                                                            > 1.4  - < 2.3
                                                            > 2.3  - < 3.9
                                                            > 3.9  - < 6.5
                                                                > 6.5
  2.1
 20.5
 56.2
 64.4
 71.4
 77.6
100.0

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                             Table C-l (continued).  PARTICLE SIZE DISTRIBUTION DATA
          TEST  18
INLET
Stage
Filter
6
5
4
3
2
1
Size Rang^e
< 0.36
> 0.36 - <
> 0.7 - <
> 1.4 - <
> 2.3 - <
> 3.9 - <
> 6.5
Cumulative Mass,
, urn Percent

0.7
1.4
2.3
3.9
6.5

2.5
13.1
44.9
55.5
59.4
61.4
100.0
                                                                               OUTLET

                                                                      Size Range, urn
                                                                          < 0.36
                                                                      > 0.36 - < 0.7
                                                                      > 0.7  - < 1.4
                                                                      > 1.4  - < 2.3
                                                                      > 2.3  - < 3.9
                                                                      > 3.9  - < 6.5
                                                                          > 6.5
Cumulative Mass,
    Percent	
      5.7
     31.1
     79.0
     84.3
     84.3
     84.3
    100.0
2
06

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                                 APPENDIX D
                       LABORATORY SIZING OF TEST DUSTS

    The test dusts used in the field program were first dispersed in the lab-
oratory and their particle size distribution determined with Andersen cascade
impactors.  The results are shown in Tables D-l and D-2 and Figures D-l and
D-2.
    The dusts were dispersed with an air ejector similar to the one used in
the Braxton dust feed system except the compressed air supplied to the
laboratory system was considerably higher (90 psi) then that supplied to the
field system (20 psi).  This probably led to more nearly complete breakup of
the agglomerates in the bulk dust and hence an aerosol of smaller particle
size than was achieved in the Braxton dust dispersion system.
    As expected the cupola dust displayed a much smaller particle size dis-
tribution than the fly ash.  Under the laboratory dispersion conditions the
mass median diameter of the cupola dust was about 1.1 micrometers and the
mass median diameter of the fly ash was about 9 micrometers.
                                     69

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Table D-l.  Particle Size Distribution for Laboratory
            Dispersed Cupola Dust
Stage
Filter
6
5
4
3
2
1
Size Range, urn
<0.36
>0.36 - <0.7
>0.7 - <1.4
>1.4 - <2.3
>2.3 - <3.9
>3.9 - <6.5
>6.5
Cumulative Mass,
Percent
16.2
32.3
54.5
54.5
54.5
54.5
100.0
Table D-2.  Particle Size Distribution for Laboratory
            Dispersed Fly Ash
Stage
Filter
6
5
4
3
2
1
Size Range, mn
<0.36
>0.36 - <0.7
>0.7 - <1.4
>1.4 - <2.3
>2.3 - <3.9
>3.9 - <6.5
>6.5
Cumulative Mass,
Percent
1.8
3.2
6.8
12.2
20.7
36.5
100.0
                          70

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  10-



   8-

   7-

   6
um
Pi
W
H
a
o

     .7


     .6


     .3
      001
               O.I
                                      10
                                                10  40  SO  6O  TO
                                                                 BO
                                                                       9O
                                                                            93
                                                                                 90   99
                                                                                              9S.9
                                                                                                    S9.99
                                   PERCENT MASS < STATED  PARTICLE DIAMETER

              Figure D-l.   Particle Size  Distribution  for  Laboratory Dispersed Cupola Dust

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  10—
  9	
  8 ~
  7 —
  6 —
  5 —

w
H
S   '-
Q    .9
a    a
0    .7
M
§    '
f^    .3
      001
              O.I
                                 5    10     2O   30  40  50  60  70  80    90   99
                                 PERCENT MASS < STATED PARTICLE DIAMETER
                                                                                 98   99
                                                                                              99.9
                                                                                                    99.99
                Figure D-2.  Particle  Size Distribution for Laboratory Dispersed  Fly Ash

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                                  TECHNICAL REPORT DATA
                           (Please read liiinmclinn* on the n-rerse before completing)
 I. HEPOHT NO.
  EPA-650/2-74-036
                             2.
                                   3. RECIF'ILNT'S ACCGSSIOIV NO.
 4. - ITLE AND SUBTITLE
 Braxton Sonic Agglomerator Evaluation
                                   5. REPORT DATE
                                     Mayl974
                                                        G. PERFORMING ORGANIZATION CODE
 7. AUTHOR(S)

 Richard Dennis, Robert Bradway, and.Reed Cass
                                   8. PERFORMING ORGANIZATION REPORT NO.
 9. PERFORMING ORGANIZATION NAME ANO ADDRESS
 GCA Corporation
 GCA/Technology Division
 Bedford, Massachusetts 01730
                                   10. PROGRAM ELEMENT NO.
                                     1AB012; ROAP 21ADL-04
                                   11. CONTRACT/GRANT. NO.

                                     68-02-1316 (Task 1)
 12. SPONSORING AGENCY NAME ANO ADDRESS
 EPA, Office of Research and Development
 NERC-RTP, Control Systems Laboratory
 Research Triangle Park, NC 27711
                                   13. TYPE OF REPORT ANO PERIOD COVERED
                                     Final
                                   14. SPONSORING AGENCY CODE
 IS. SUPPLEMENTARY NOTES
 16. ABSTRACT,
          The report'is an evaluation of a novel air pollution control system developed
 by the Braxton Corporation.  The alternating velocity precipitator, or sonic  agglom-
 erator, is designed to decrease the number and increase the size of particles in a
 gas stream by agglomeration induced by a standing sound wave through which the
 aerosol moves. A prototype alternating velocity precipitator was tested to.determine
 its basic performance characteristics and to evaluate the effect of adding water and/
 or steam to the systems performance.^ Tests  indicate that the  device decreases the
 mass of fine particles but that the reduction is more highly correlated to the use of
 water sprays than to the use of the sonic generator. The correlation coefficients
 relating the use of sound and water sprays to  fine particle reduction, however, were
 not statistically significant.  The particle size distributions of the fine  particles at
 both the inlet and outlet of the  sonic agglomerator were determined with Andersen
 cascade impactors.  Although shifts between the inlet and outlet size distributions
 were often observed,  there was no clear trend to the changes and they  could not be
 correlated to system operating parameters.
 7.
                              KEY WORDS AND DOCUMENT ANALYSIS
                 DESCRIPTORS
                                           b.lDENTIFIERS/OPEN ENDED TERMS
                                               c. COSATI l-'icld/Croup
 Air Pollution
 Acoustics
 Precipitators
 Agglomeration  .
 Particle Size
 Particle Size Distribution
 "as Flow
Aerosols
Sound Waves
 Air Pollution Control
 Stationary Sources
Braxton Sonic Agglom-
   erator
 Alternating Velocity
   Precipitator
 Particulates	
13B
20A
7A
7D
                                               20D
 i. uiurmuurioN STATEMENT
 Unlimited
                                           19. SE.CUHITY CLASS (Tills Krporl)
                                           Unclassified
                                                                    21. NO. OF CAGES
                                           20. SECURITY CLASS (Thil pagt)
                                           Unclassified
                                                                    22. PRICE
E/-A Form 2220-1 (9-73)

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