vvEPA United States Environmental Protection Agency Industrial Environmental Research Laboratory Research Triangle Park NC 27711 EPA-600/8-78-005c June 1978 Research and Development Particulate Control Highlights: Flux Force/ Condensation Wet Scrubbing F/C SCRUBBER DEMONSTRATION PLANT AJ>T - E.PA. ------- RESEARCH REPORTING SERIES Research reports of the Office of Research and Development, U.S. Environmental Protection Agency, have been grouped into nine series. These nine broad cate- gories were established to facilitate further development and application of environmental technology. Elimination of traditional grouping was consciously planned to foster technology transfer and a maximum interface in related fields. The nine series are: 1. Environmental Health Effects Research 2. Environmental Protection Technology 3. Ecological Research 4. Environmental Monitoring 5. Socioeconomic Environmental Studies 6. Scientific and Technical Assessment Reports (STAR) 7. Interagency Energy-Environment Research and Development 8. "Special" Reports 9. Miscellaneous Reports This report has been assigned to the SPECIAL REPORTS series. This series is reserved for reports which are intended to meet the technical information needs of specifically targeted user groups. Reports in this series include Problem Orient- ed Reports, Research Application Reports, and Executive Summary Documents. Typical of these reports include state-of-the-art analyses, technology assess- ments, reports on the results of major research and development efforts, design manuals, and user manuals. EPA REVIEW NOTICE This report has been reviewed by the U.S. Environmental Protection Agency, and approved for publication. Approval does not signify that the contents necessarily reflect the views and policy of the Agency, nor does mention of trade names or commercial products constitute endorsement or recommendation for use. This document is available to the public through the National Technical Informa- tion Service, Springfield, Virginia 22161. ------- EPA-600/8-78-005C June 1978 Particulate Control Highlights: Flux Force/Condensation Wet Scrubbing by S. Calvert and R. Parker Air Pollution Technology, Inc. 4901 Morena Boulevard, Suite 402 San Diego, California 92117 Contract No. 68-02-2190 Program Element No. EHE624 EPA Project Officer: Dennis C. Drehmel Industrial Environmental Research Laboratory Office of Energy, Minerals, and Industry Research Triangle Park, NC 27711 Prepared for U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Research and Development Washington, DC 20460 ------- ABSTRACT Flux force/condensation (F/C) scrubbing involves the use of water vapor condensation effects to enhance fine particle collec- tion. F/C scrubbing offers significant cost advantages over con- ventional control equipment for a large number of industrial sources. Generally it is attractive when high removal efficien- cies are required for fine particles; and the flue gas enthalpy is sufficiently high or spent steam is available. The EPA fine particle scrubber program has been instrumental in identifying, understanding, and quantifying flux force and condensation effects in wet scrubbers. EPA also has taken a leading role in developing and demonstrating F/C scrubbers for industrial applications. ------- CONTENTS Abstract ii Figures iv Tables iv Introduction 1 F/C Scrubber Development. . 1 Early Development 2 Demonstration Plants 3 Design Considerations 3 Particle Size Distribution 4 Particle Number Concentration 4 Particle Condensation Ratio 4 Particle Properties 5 Contribution of Flux Forces 5 Practical Applications 6 General Features 6 Steam Introduction 7 Economic Feasibility 8 Conclusions 8 Bibliography 15 ill ------- FIGURES Number Page 1 Simplified F/C Scrubber System 12 2 Particle Size Distribution Before and After Condensation for 109 Particles/DNcm3 13 3 Generalized Process Design for F/C Scrubber System. 14 4 Predicted Performance for F/C Venturi Scrubber. . . 15 TABLES Number Page 1 Major Industrial Particulate Sources for Which F/C Scrubbing is Attractive 9 2 Cost Comparison of Cupola Emission Control System . 10 3 Cost Comparison for Premium Wire Recovery 11 iv ------- ABBREVIATIONS AND SYMBOLS CFM - cubic feet per minute DNm3/min - dry normal m3/min (at 1 atm, 20°C) F/C - flux force and condensation n - particle number concentration, cm psig - pounds per square inch gage ymA - aerodynamic micrometers, urn yg/cnr PG - air density, g/cm3 p - particle density, g/cm3 v ------- FLUX FORCE/CONDENSATION WET SCRUBBING INTRODUCTION In 1970, the EPA fine particle scrubber program was ini- tiated with the Wet Scrubber Systems Study. The principal result was the publication of the Scrubber Handbook (Calvert, et al., 1972), reviewing the state-of-the-art and pointing out several paths which might lead to improvements in scrubber technology. Since 1972, the broad objective of the EPA program has been to develop and demonstrate low pressure drop (30-50 cm water column) scrubber systems capable of collecting at least 90% by mass of particles smaller than 3 ym in diameter. A major drawback with conventional wet scrubbers is the large energy expenditure required to achieve high removal efficiencies for particle diameters smaller than 2 to 3 ym. Primarily this is a result of the decreased effectiveness of inertial mechanisms for separating very small particles from a gas stream. The Wet Scrubber Systems Study recommended investigating phenomena which can exert forces other than inertial forces on particles and where warranted, developing equipment to use these forces for particle collection. Along this line, a major thrust has been aimed at developing and demonstrating flux force/conden- sation (F/C) scrubbers. F/C SCRUBBER DEVELOPMENT Essentially an F/C scrubber is any wet scrubber which is designed to take advantage of water vapor condensation effects to enhance particle collection. A simplified F/C scrubber system is illustrated schematically in Figure 1. Some of the water vapor condenses on the particles causing their mass and diameter to increase and thereby making them easier to collect. The rest of ------- the condensing vapor sweeps particles with it as it moves toward the cold surface and condenses. To a lesser extent particle collection is also enhanced by thermal forces resulting from the temperature gradient between the gas and the cold surface. The diffusion and thermal forces are termed "flux" forces. Investigators had realized for years that anomalously high collection efficiencies could be obtained at relatively low pres- sure drops when water vapor condensation occurred ahead of the scrubber. However, no systematic investigation had been conduc- ted which could be used to design and optimize scrubbers to take advantage of flux force and condensation effects. Since 1972 the EPA has taken a leading role in this area, developing F/C scrub- bing through theoretical, laboratory, pilot plant and full scale industrial demonstration plant projects. Early Development The feasibility of F/C scrubbing for fine particulate control was investigated and reported by Calvert, et al. (1973) and Calvert and Jhaveri (1974). The work involved extensive theo- retical studies and exploratory experiments on a bench scale. Preliminary engineering and cost analyses were conducted and it was recommended that pilot scale F/C scrubbers be built and tested, Two pilot scale F/C scrubbers were built to handle from 14 to 28 m3/min (500-1,000 CFM) actual gas flow rate. Based on the results of the bench scale work, multiple sieve plate and hori- zontal spray scrubber configurations were selected for the pilot study. The results were very promising both from a technological and from an economic point of view. Depending on the process characteristics, the operating costs for an F/C scrubber were predicted to be as low as 1/3 or less of the operating cost for an equivalent high energy scrubber. Details of the pilot plant studies were reported by Calvert, et al. (1975) and Calvert and Yung (1976). ------- Demonstration Plants EPA has funded two full-scale industrial F/C scrubber demon- stration plants. The first demonstration plant was a multiplate F/C scrubber used to control fine particle emissions from a secondary metal recovery furnace. Control of the entire source effluent (200 m 3/min or 7,000 ACFM) at temperatures up to 800°C required both particle collection and acid gas absorption. The demonstration plant performance was consistent with the earlier bench-scale and pilot-scale studies. The system was generally capable of about 901 to 95% effi- ciency on particles with a mass median aerodynamic diameter of 0.7 to 0.8 ymA (about 0.3 ym physical diameter for particles with a density of 4.0 g/cm3). This efficiency was achieved with a 68 cm (27 in) W.C. gas phase pressure drop. A conventional high energy scrubber without F/C effects would have required pressure drops of roughly 250 cm (98 in) W.C. for 901 and 535 cm (210 in) W.C. for 95% particle collection efficiency. Detailed results and economic analyses for the demonstration plant have been reported by Calvert, et al. (1977) and Calvert and Gandhi (1977). The second F/C scrubber demonstration currently is underway. A gas-atomized spray F/C scrubber will be used to control fine particle emissions from a gray iron foundry cupola. Plant startup is scheduled for late fall, 1978. DESIGN CONSIDERATIONS One of the major goals of the EPA F/C scrubbing development program has been to quantify the important F/C effects by identi- fying key process parameters and developing useful engineering models for design and performance prediction purposes. This goal has been achieved through the systematic development and demon- stration program described above, resulting in a simplified and improved design method for F/C scrubbing as reported by Calvert and Gandhi (1977) . The most important parameters and design concepts are discussed briefly on the following pages. ------- Particle Size Distribution One of the most important design parameters for any particu- late control device is the particle size distribution. In an F/C scrubber there are two size distributions which must be considered. The initial size distribution is that leaving the source and enter- ing the saturator and condenser. This size distribution is used to predict the collection efficiency in the saturator and initial stages of the condenser before condensation occurs. It also is important in determining the final size distribution after conden- sation. The final or "grown" particle size distribution is that which results from water vapor condensation on the particles. Typical initial and grown particle size distribution curves are shown in Figure 2. A convenient design assumption is that each particle receives the same mass of condensing vapor, independent of the particle diameter. This explains the observation that small particles grow much more than large particles. Although this assumption is not strictly valid, it agrees well with experi- mental observation for particle diameters of interest (larger than about 0.1 ym). Particle Number Concentration Because all particles receive an approximately equal mass of condensate, the number concentration of particles is very impor- tant in determining the final grown particle size. Particle num- ber concentration is not generally an important parameter for other particulate control techniques and therefore it often is difficult to find adequate data. However, these data are essential for pro- per design of F/C scrubbing systems. Representative number con- centrations for industrial sources can range from about 107 to 109 particles/DNcm3. Particle Condensation Ratio Most of the water vapor will condense on the cold, solid or liquid surfaces of the condenser. Only a fraction of the vapor will condense on the particles. This fraction is called the ------- particle condensation ratio. It is affected by many parameters including: inlet gas temperature, bulk liquid temperature, particle number concentration, particle diameter, liquid phase heat transfer coefficient, and condenser geometry. Particle condensation ratios ranging from 15% to 40% have been predicted for several combinations of parameters in a sieve plate condenser. For a combination of parameters such as might be encountered in a practical situation a value of 0.25 appears to be reasonable for a plate type condenser. This is equivalent to saying that 25% of the condensing vapor goes to the particles and 75% goes to the cold surfaces. Particle Properties In the design model, particles are assumed to be wettable, but insoluble. If the emitted particles were soluble in water, the expected performance for the system would be better. The solubility of the particles in water would depress the vapor pres- sure at the particle-gas interface, resulting in nucleation at a lower saturation ratio and more growth at a given saturation ratio. Particle density also is important. This usually is accounted for by using the particle aerodynamic diameter for all particle collection calculations. The difference in particle and liquid densities must be considered when predicting grown aerodynamic dia- meters . Contribution of Flux Forces Particle collection by thermal gradient forces (thermophoresis) is only of minor importance and usually is neglected when predicting the performance of an F/C scrubber. Diffusion flux forces (diffusiophoresis) however, are sig- nificant and must be considered. Detailed mathematical models exist for predicting diffusiophoretic deposition velocities and particle collection efficiencies. These models are complicated and cumbersome to use, requiring a step-by-step numerical integra- tion over the period of condensation. Whitmore (1976) discovered that the fraction of particles removed by diffusion of the condensing vapor is approximately equal to the fraction of the gas which condenses. In other words, if some fraction of the gas is transferred to the liquid phase it ------- will carry along its load of suspended particles. It turns out that this simplifying assumption is extremely useful for design pur- poses if modified to account for the molecular weight gradient and the fraction of condensate which condenses on particles. PRACTICAL APPLICATIONS In general, F/C scrubbing is attractive economically when high removal efficiencies are required for fine particle emissions; and the flue gas enthalpy is higher than 100 kcal/kg or spent steam is available in the plant. These conditions are common for industrial combustion processes, which include several major stationary pollution sources in the United States. Table 1 lists some of the major industrial particulate pollutant sources for which F/C scrubbing is attractive. It is clear that F/C scrubbing is a feasible and attractive particulate control method for several major industrial sources. General Features Although the details of F/C scrubbing system designs will be different for each source, the overall process designs will be similar to that shown in Figure 3. Some general economic features of F/C scrubbing are discussed below. Experimental pilot plant results indicate that it should require from 0.1 to about 0.3 g water vapor condensed/g dry gas in a F/C scrubber to attain high collection efficiency for fine particles. Such a condensation ratio generally requires preconditioning of the scrubber inlet gas to increase its moisture content. Gas preconditioning could be done either by direct intro- duction of spent steam if the gas is dry and has low enthalpy, or by evaporation of sprayed water when enough enthalpy is avail- able in the gas. Direct injection of steam is beneficial because it can increase the local saturation ratio appreciably higher than 1.0, which is necessary to initiate the growth of hydrophobic particles. Cooling water is needed to condense the desired amount of vapor in the scrubber. In an industrial system the water is ------- cooled in an evaporative cooling tower using ambient air, and then recirculated to the F/C scrubber. In cooling towers of conventional design, the change in water temperature is kept below about 17°C (30°F). A larger water temperature differential can be achieved in cooling towers of special design but the costs will be higher than usual, and there may be undesirable features such as fog formation. If the water temperature increase in the scrubber is 17°C (30°F), about 32 g of cooling water will be required to condense 1 g of water vapor. Steam Introduction While the performance of an F/C scrubber at a given conden- sation ratio is better if part or all of the water vapor is intro- duced as steam (i.e, 100% HaO), the cost of purchased steam will generally be prohibitively high. However, under the right cir- cumstances the use of some steam introduction could be economical. The steam required for injection could be low pressure, less than 2 atm gage (30 psig) spent steam. It may be obtained from the feed line to the boiler condenser in a process plant or generated in a low pressure waste boiler in a metallurgical operation. In this case, the steam cost would be significantly lower and will depend on the specific manufacturing process. Figure 4 shows the predicted penetration for an F/C venturi scrubber as a function of condensation ratio and gas phase pres- sure drop. These predictions are conservative in that they assumed the initial particle nuclei had negligible mass and dia- meter. The amount of steam required to achieve a given penetra- tion at a specified pressure drop is equivalent to "q1". The economics of steam generation will depend on the required pene- tration and the savings in power usage associated with the lower pressure drop required for F/C scrubbers. In general, a F/C scrubber using some purchased steam would have lower operating costs compared to a venturi scrubber. Also, the most important mechanisms in F/C scrubbing (diffusiophoresis and particle growth by condensation) are practically insensitive to particle size. Thus, F/C scrubbing would become economically ------- more attractive as the size of the particles to be controlled becomes smaller. Economic Feasibility The economic feasibility of an F/C scrubber system used to control emissions from a gray-iron foundry cupola was reported by Calvert, et al. (1975). A comparison between the estimated costs of the F/C scrubber system and a conventional high energy scrubber system are presented in Table 2. Both capital and operating costs are cheaper with the F/C scrubber system. The largest difference is in the power costs where the lower pressure drop required for F/C scrubbing results in substantial savings. Based on the results of the first demonstration plant, an optimum design for an F/C scrubber was obtained for controlling emissions from a premium wire recovery furnace. The costs are compared with a conventional high energy scrubber in Table 3. CONCLUSIONS The EPA fine particle scrubber program has been instrumental in identifying, understanding, and quantifying flux force and condensation effects in wet scrubbers. As a result, it is now possible to use a proven engineering design model to design F/C scrubbers for new sources, or to modify existing scrubbers to take better advantage of F/C effects. EPA has demonstrated on laboratory, pilot and industrial scales, that F/C scrubbing is technologically feasible and attractive. Furthermore, F/C scrubbing offers very significant cost savings over conventional control equipment for a large number of industrial sources. EPA involvement in F/C scrubbing is continuing with further industrial demonstration projects. ------- TABLE 1. MAJOR INDUSTRIAL PARTICIPATE SOURCES FOR WHICH F/C SCRUBBING IS ATTRACTIVE INDUSTRY Iron § Steel ;orest Products .ime Primary Non ferrous Aluminum Copper Zinc Lead Asphalt Ferroalloys Iron Foundry Secondary Nonferrous Metals Copper Aluminum Lead Zinc SOURCE Sinter Plants Coke Manufacture Blast Furnaces Steel Furnaces Scarfing Wigwam Burners Pulp Mills Rotary Kilns Vertical Kilns Calcining Reduction Cells Roasting Reverberatory Furnaces Converters Roasting Sintering Distillation Sintering Blast Furances Dross Reverberatory Furances Paving Materials Roofing Materials Blast Furnaces Electric Furnaces Furnaces Material Preparation Smelting and Refining Sweating Furnaces Refining Furnaces Chlorine Fluxing Pot Furnaces Blast Furnaces Reverberatory Furances Sweating Furnaces Distillation Furnaces ------- TABLE 2. COST COMPARISON OF CUPOLA EMISSION CONTROL SYSTEMS COST ITEMS HIGH ENERGY F/C SCRUBBER SCRUBBER SYSTEM SYSTEM ($3 CD ($) A. Capital Costs 1. F.O.B. quencher with internals, flange to flange. (4) 16,050 2. F.O.B. scrubber with internals, flange to flange including entrainment separator 24,590 42,910 3. F.O.B. cooling tower -- 46,200 4. Fans, motors and motor starter 206,690 46,260 5. Liquid treatment and solid handling equip- ment, including pumps 66,130 105,740 6. Piping and ducting (2) 159,370 135,580 7. Instrumentation and electrical material (3) 30,270 20,670 TOTAL EQUIPMENT COST - 487,050 413,410 B. Annual Operating Costs 1. Electrical power for fans and pumps 159,170 60,370- 2. Annualized capital charges and depreciation (20% of capital costs) 97,410 82,680 TOTAL $256,580 $143,050 Notes 1. Actual costs obtained from the user, converted to 1978 2. Due to equivalent complexity, the costs were assumed same for both systems. 3. Taken as 51 of equipment costs for the F/C system. 4. Quench spray costs for both the systems are included in the ducting costs. 10 ------- TABLE 3. COST COMPARISON FOR PREMIUM WIRE RECOVERY COST ITEM Venturi Cooling Tower Condenser Saturator Blower § Motor Total Equipment Total Capital Investment Depreciation Maintenance Water Raw Materials Power Total Annual Cost COST FOR F/C $ 1,700 8,900 4,040 5,060 3,790 23,490 $103,121 $10,310 6,185 180 1,650 2,370 $20,695 COST FOR CONVENTIONAL $ 1,700 0 4,040 5,060 14,450 25,340 $111,242 $ 11,125 6,675 180 1,650 11,530 $31,160 11 ------- CLEAN GAS i WATER —£>• SCRUBBER SATURATED GAS WATER —M CONDENSER ^SATURATED GAS WATER U>|PRECONDITIONER| HOT GAS Figure 1. Simplified F/C scrubber system. 12 ------- 3.0 I I 1.0 W H W o w u I—I OS GROWN 0.5 0.1 Figure 2. INITIAL I I I i I I 10 30 50 70 DRY MASS % UNDERSIZE 90 95 98 Particle size distribution before and after condensation for 109 particles/DNcm3. 13 ------- TO STACK AIR FROM SOURCE I UJ Cf CITY. WATER AIR TO DRAIN OR LIQUID TREATMENT Figure 3. Generalized process design for F/C scrubber system. ------- i.o. PI o o rt 0.5 0.2 0.1 0.05 0.02 0.01 0.005 0.002 0.001 I i VENTURI AP = 50 cm W.C, PREDICTED Pt VERSUS q' FOR F/C VENTURI SCRUBBER I i I I I 0.01 0.05 0.1 0.5 q', g H20 CONDENSED/g DRY AIR 1.0 Figure 4. Predicted performance for F/C venturi scrubber. Initial particle diameter=0, n =10B particles/cm3, 20% condensate on particles, pA = 0.0011 g/cm3, Pp = 1.0 g/cm3. 15 ------- BIBLIOGRAPHY Calvert, S., et al., "Scrubber Handbook," EPA-R2-72-118a, NTIS PB 213-016, July 1972. Calvert, S., et al., "Feasibility of Flux Force/Condensation Scrubbing for Fine Particulate Collection," EPA-650/2- 73-036, NTIS PB 227-307, October 1973. Calvert, S., and N.C. Jhaveri, "Flux Force/Condensation Scrubbing," Proceedings of the EPA Fine Particle Scrubber Symposium, San Diego, CA, May 1974, EPA-650/2-74-112, NTIS PB 239-335, 1974. Calvert, S., et al., "Study of Flux Force/Condensation Scrubbing of Fine Particles," EPA-600/2-75-018, NTIS PB 249-297, August 1975. Calvert, S., and S.C. Yung., "Study of Horizontal Spray Flux Force/Condensation Scrubber," EPA-600/2-76-200, NTIS PB 262-669, July 1976. Calvert, S., and S. Gandhi, "Improved Design Method for F/C Scrub- bing," Proceedings of Second EPA Fine Particle Scrubber Symposium, New Orleans, LA, May 1977, EPA-600/2-77-193, NTIS PB 272-828, September 1977. Calvert, S., et al., "F/C Scrubber Demonstration on a Secondary Metals Recovery Furnace," Pro'ceedings of Se_eond EPA Fine Particle Scrubber Symposium, New Orleans, LA, May 1977, EPA-600/2-77-193, NTIS PB 273-828, September 1977. Calvert, S., and S. Gandhi, "Fine Particle Collection by a Flux Force/Condensation Scrubber: Pilot Demonstration," EPA-600/2-77-238, NTIS PB 277-075, December 1977. Whitmore, P.J., "Diffusiophoretic Particle Collection Under Turbulent Conditions," Ph.D. Thesis, University of British Columbia, Canada, 1976. 16 ------- TECHNICAL REPORT DATA (Please read Instructions on the reverse before completing) REPORT NO. EPA-600/8-78-005c 3. RECIPIENT'S ACCESSION NO. . TITLE ANDSUBTITLE Particulate Control Highlights: Flux Force/Conden- sation Wet Scrubbing REPORT DATE June 1978 . PERFORMING ORGANIZATION CODE . AUTHOH(S) 8. PERFORMING ORGANIZATION REPORT NO. . Calvert and R. Parker . PERFORMING ORGANIZATION NAME AND ADDRESS Air Pollution Technology, Inc. 4901 Morena Boulevard, Suite 402 San Diego, California 92117 10. PROGRAM ELEMENT NO. EHE624 11. CONTRACT/GRANT NO. 68-02-2190 12. SPONSORING AGENCY NAME AND ADDRESS EPA, Office of Research and Development Industrial Environmental Research Laboratory Research Triangle Park, NC 27711 13. TYPE OF REPORT AND PERIOD COVERED Task Final; 10/77-4/78 14. SPONSORING AGENCY CODE EPA/600/13 15. SUPPLEMENTARY NOTES jjERL-RTP project officer is Dennis C. Drehmel, Mail Drop 61, 919/541-2925. 16. ABSTRACT The report gives highlights of EPA's flux force/condensation (FF/C) program, a system that involves the use of water vapor condensation effects to enhance fine particle collection. FF/C scrubbing offers significant cost advantages over conventional control equipment for a large number of industrial sources. Generally, it is attractive when high removal efficiencies are required for fine particles, when flue gas enthalpy is sufficiently high, or when spent steam is avail- able. EPA's fine particle scrubber program has been instrumental in identifying, understanding, and quantifying flux force and condensation effects in wet scrubbers. EPA also has taken a leading role in developing and demonstrating FF/C scrubbers for industrial applications. 17. KEY WORDS AND DOCUMENT ANALYSIS DESCRIPTORS b.lDENTIFIERS/OPEN ENDED TERMS COSATI Field/Group Air Pollution Dust Flux Density Condensating Gas Scrubbing Air Pollution Control Stationary Sources Particulates Flux Force/Condensa- tion Scrubbing 13 B 11G 07D 07A,13H 13. DISTRIBUTION STATEMENT Unlimited 19. SECURITY CLASS (This Report) Unclassified 21. NO. OF PAGES 22 20. SECURITY CLASS (Thispage/ Unclassified 22. PRICE EPA Form 2220-1 (9-73) 17 ------- |