LSR Technologies, Inc.
898 Main Street, Acton, MA 01720
/.Isrtech.com
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DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, LSR Technologies, Inc., has developed the Core
Separator, a mechanical dust-collecting device that re-
moves micron- and submicron-sized particles from gas
streams. Historically, mechanical collectors have been
ineffective in removing particles with diameters of less
than 10 microns.
The Core Separator System includes two conventional
components, a cyclone collector for extracting solids and
a fan for flow recirculation. A complete system is actu-
ally a multitude of cylindrical units, each with a single
inlet for the stream to be treated and two outlets. One
outlet is for the clean gas stream and the other contains
a highly concentrated recirculation stream. The dust-
laden recirculation stream is fed to a cyclone and re-
turned again by means of the fan. The Core Separator
component cleans the inlet stream and detains dust par-
ticles in the system. Because its efficiency is very high,
most particles do not leave the system. They recirculate
until collected by the cyclone. Two factors govern the
performance of Core Separators: (1) high separation
efficiency of the separator component, and (2) the in-
teraction between individual components. To achieve
high separation efficiency, a proper bleed-flow ratio (i.e.,
ratio of the recirculation flow to the total flow) is re-
quired. By controlling bleed flow, the tangential and
radial velocities are controlled independently to main-
tain them in the desirable range.
High efficiency in the Core Separator results from low
particle reentrainment. The system is designed to avoid
formation of toroidal vortices. Because the Core Separa-
tor component functions as a separator and not a collec-
tor, a flow U-turn within the device can be avoided. It is
entirely cylindrical, and surfaces promoting the forma-
tion of vortices are moved away from the clean outlet.
This theory has been verified by actual testing and
through computer modeling using computational fluid
dynamics to study flow fields. It should be noted that each
of these factors individually cannot prevent vorticity; how-
ever, working together they achieve what each cannot
independently. The conflicting processes of separation
and solids collection are accomplished separately and in
different components. The interaction between compo-
nents is the principal means of attaining high system ef-
ficiency.
SIGNIFICANCE OF THE TECHNOLOGY
Particulate matter is being regulated as a criteria air pol-
lutant (i.e., pollutants causing human health impacts due
to their release from numerous sources) under the Clean
Air Act. EPA has proposed tightening the National Ambi-
ent Air Quality Standards for the allowable levels of par-
ticulate matter, decreasing the size of the particles that
must be removed from gas streams from 10 microns to 2.5
microns. Unlike other mechanical collectors, the Core
Separator is capable of removing dust particles with di-
ameters of less than 10 microns; it even can remove a
high percentage of particles in the micron range. This is
equivalent to the performance of a medium-efficiency
4- LSR Technologies' Core Separator can remove micron- and submicron-sized particles from gas streams.
4- By removing micron-sized particles from gas streams, the Core Separator reduces particulate matter
emissions and the human health and environmental effects associated with this criteria air pollutant.
4- More than 65 Core Separators have been sold in the United States and abroad. These units are attributed
with a major reduction of particulate air emissions. For example, stack compliance testing has shown
particulate emissions to be below 100 mg/nm3 when used on coal-fueled boilers.
4- A Core Separator installation used for recovery of chemical catalysts by a Fortune 500 company has
produced a payback in less than 6 months.
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Clean Flow
Core Separators
Cyclones
Solids
Flew
Recirculation Lines
LSR Technologies' Core Separator System con-
sists of a series of cylindrical units, each with a
single inlet for the stream to be treated and two
outlets. One outlet is for the clean gas stream
and the other is for the highly concentrated re-
circulation stream. The dust-laden recirculation
stream is fed to a cyclone where solids are ex-
tracted and returned again by means of the fan,
which facilitates flow recirculation.
More than 65 Core Separators, such as
the one at the asphalt plant above, have
been installed in the United States and
other countries to remove dust particles
from gas streams.
electrostatic precipitator and better than the performance
of a high-energy Venturi scrubber. Yet, the Core Separa-
tor still has the traditional advantages of mechanical col-
lectors such as simplicity, reliability, compactness, and low
maintenance.
COMMERCIALIZATION SUCCESS
There is strong demand for the Core Separator both as
an air pollution control device and as a means to recover
valuable product material. More than 65 Core Separa-
tors have been sold in the United States and abroad, and
at least one company using the technology for recovery of
chemical catalysts has experienced a payback period of
less than 6 months. This product is quite significant in
light of the fact that very few advances have occurred in
particulate control technology in recent years.
Another emerging industrial application for the Core
Separator is as a control device for collecting particulate
matter upstream of regenerative thermal oxidizers, which
are used in the production of wood products for the build-
ing industry (e.g., medium-density fiberboard, particle-
board, and oriented strandboard). The Core Separator
currently is being demonstrated for wood dryer applica-
tions, and could emerge as the "Best Available Control
Technology" for these processes.
AWARDS AND COMPANY HISTORY
In 1996, the Core Separator was selected for the
prestigious R&D 100 Award, signifying it as one
of the world's best new technology-based prod-
ucts of the year. LSR Technologies, Inc., is a Mas-
sachusetts-based engineering firm that offers
emission control and process equipment to in-
dustrial clients. The company has supplied in-
novative equipment and novel solutions for difficult in-
dustrial separations since 1989. LSR equipment is in
operation in numerous plants around the world for prod-
uct recovery and for emissions control. LSR equipment
applications include minerals and metals processing, re-
covery of chemicals and catalysts, coal-fired power plants,
furnaces, dryers, acid gas removal, and wood-fired boilers.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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