Electrostatic precipitator dust precipitation

These gases leave the furnace at about 600 K. pass through electrostatic precipitators to remove dust, and the phosphorus is then condensed out. 

In all the above methods, the sulphur dioxide obtained is impure. Dust is removed by first allowing the gases to expand, when some dust settles, then by passage through electrostatic precipitators and finally by washing with water. Water is removed by concentrated sulphuric acid which is kept in use until its concentration falls to 94%. 

Air cleaning systems are often used to remove dust or vapors from plant or process exhaust streams. Dust collecting systems such as filters or electrostatic precipitators that handle heavy loads of dust are usually designed to be self-cleaning, but it is stiU. necessary to enter the air cleaner periodically for inspection or repair. Dust deposits inside the equipment are likely to be stirred up and inhaled by unprotected workers. Baghouses are particularly likely to cause exposure because large amounts of dust may be retained in the cloth and released when the bags are handled. 

Cooled dust-laden gas is dedusted in an electrostatic precipitator and sent to the cleaning unit to remove impurities such as arsenic, fluorine, and chlorine before being sent on to the sulfuric acid production plant. 

The combined flue dust from waste heat boiler and electrostatic precipitator, including dust from the ventilation system, is collected in a bin and recirculated to the mixing and pelletizing step, where it is used as a binding reagent. 

N2, and traces of PH, CO2, E, and S large furnaces generate off-gas at a rate of about 120—180 m /min. In most installations the off-gas is passed through a series of Cottrell electrostatic precipitators which remove 80—95% of the dust particles. The precipitators ate operated at temperatures above the 180°C dew point of the phosphoms. The collected dust is either handled as a water slurry or treated dry. Einal disposal is to a landfill or the dust is partially recycled back to the process. The phosphoms is typically condensed in closed spray towers that maintain spray water temperatures between 20 and 60°C. The condensed product along with the accompanying spray water is processed in sumps where the water is separated and recycled to the spray condenser, and the phosphoms and impurities ate settled for subsequent purification. 

Handling of alumina and coke presents dusting problems. Hoods and exhaust systems collect the dust, which is then separated from the exhaust air either by cyclones, electrostatic precipitators, filter bags, or a combination of these methods, and recycled to the process (see Air pollution control PffiTHODS). 

Cement plants in the United States are now carehiUy monitored for compliance with Environmental Protection Agency (EPA) standards for emissions of particulates, SO, NO, and hydrocarbons. AH plants incorporate particulate collection devices such as baghouses and electrostatic precipitators (see Air POLLUTION CONTROL methods). The particulates removed from stack emissions are called cement kiln dust (CKD). It has been shown that CKD is characterized by low concentrations of metals which leach from the CKD at levels far below regulatory limits (63,64). Environmental issues continue to be of concern as the use of waste fuel in cement kilns becomes more widespread. 

Baking Particulates (dust), CO, SO2, hydrocarbons, and fluorides High-efficiency cyclone, electrostatic precipitators, scrubbers, catalytic combustion or incinerators, flares, baghouse... 

Pot charging Particulates (dust), CO, HF, SO, CF4, and hydrocarbons High-efficiency cyclone, baghouse, spray towers, floating-bed scrubber, electrostatic precipitators, chemisorption, wet electrostatic precipitators... 

Kiln operations rotary kiln Particulates (dust), CO, SO, NO, hydrocarbons, aldehydes, ketones Electrostatic precipitators, acoustic horns and baghouses, scrubber... 

Chnker coohng materials handling Particulates (dust) Local exhaust system and electrostatic precipitators or fabric filters... 

Zinc Roasting Sintering Calcining Retorts electric arc Particulates (dust) and SO2 Particulates (dust) and SO2 Zinc oxide fume, particulates, SO2, CO Exhaust system, humidifier, cyclone, scrubber, electrostatic precipitator, and acid plant Exhaust system, humidifier, electrostatic precipitator, and acid plant Exhaust system, baghouse, scrubber or acid plant... 

RooBng plants (asphalt saturators) Felt or paper saturators spray section, asphalt tank, wet looper Crushed rock or other minerals handling Asphalt vapors and particulates (liquid) Particulates (dust) Exhaust system with high inlet velocity at hoods (3658 m/s [>200 ft/min]) with either scrubbers, baghouses, or two-stage low-voltage electrostatic precipitators Local exhaust system, cyclone or multiple cyclones... 

Electric steel furnaces charging, pouring, oxygen blow Fumes, smoke, particulates (dust), CO Segregating dirty scrap proper hooding, baghouses or electrostatic precipitator... 

Dry aerosols, or particulate matter, differ so much from the carrying gas stream that their removal should present no major difficulties. The aerosol is different physically, chemically, and electrically. It has vastly different inertial properties than the carrying gas stream and can be subjected to an electric charge. It may be soluble in a specific liquid. With such a variety of removal mechanisms that can be applied, it is not surprising that particulate matter, such as mineral dust, can be removed by a filter, wet scrubber, or electrostatic precipitator with equally satisfactory results. 

Small solid particles, present in dust and grit emissions, have very low settling velocities (Table 4.4) The collection efficiencies of simple cyclones are tlierefore, as shown in Figure 17.3, relatively low. Fabric filters, electrostatic precipitators or wet scrubbers may be required to remove particles <5 pm in size with an acceptable efficiency. Therefore the cost of pollution control inevitably increases when dealing with particle size distributions skewed towards the lower end. 

The catalyst dust is then separated from the resulting carbon dioxide stream via cyclones and/or electrostatic precipitators and is sent off-site for disposal or treatment. Generated wastewater is typically sour water from the fractionator containing some oil and phenols. Wastewater containing metal impurities from the feed oil can also be generated from the steam used to purge and regenerate catalysts. 

Give preference to fabric filters over wet scrubbers or wet electrostatic precipitators (ESPs) for dust control. 

Fabric filters can be more costly to operate and maintain than electrostatic precipitators, cyclones, and scrubbers however, fabric filters are more practicable for filtration of specific dusts. For example fabric systems are the typical control method for toxic dusts from insecticide manufacturing processes, salt fumes from heat treating, metallic fumes from metallurgical processes, and other applications. Any other control method may not be as efficient, nor economically feasible for such applications. 

Most of the results presented in the previous chapters are based on idealized conditions. In practice, the performance of an electrostatic precipitator can be significantly influenced by the dust layers on discharge and collection electrodes i.e., dust layers may alter the electrical properties of the system. It is also possible that dust layers are not stable i.e., collected particles become loose, increasing the particle concentration in the outlet of the precipitator. These problems play a much smaller role if the surface collection electrode is continuously flushed with water. These wet elearostatic precipitators, however, cannot be used in all applications. 

Thus, the corona voltage is normally adjusted to compensate for the adverse effects of a dust layer i.e., the operating conditions of the electrostatic precipitator are kept as ideal as possible. 

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