Process Emission Controls

Furnace gases and lead fumes, together with dressing dusts, must be captured and contained. There are a variety of methods to do this, but the most effective are filtration plants. 

An alternative to the filter bag is an electrostatic precipitator. In these baghouses, an electric field at high potential is established between discharge and collecting electrodes. The discharge electrode has a small cross-sectional area (e.g., a wire or piece of flat stock), while the collection electrode is large in surface area (e.g., a plate). 

As a further stage to ensure the removal of any small particles of dust, flue gas can be directed to a Venturi-type dust collector. At both the Met and the outlet of this type of collector, dust is covered by condensate through adiabatic expansion and collected by sprayed water that is circulated via tanks installed at the inlet and the outlet, respectively. This system is also a useful preparation for the removal of traces of sulfur dioxide by passing the gases through an absorber tower where the sulfur oxides are removed by contact with circulating water that is sprayed into the tower. 

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Those, on industrial applications orientated systems, are acoustic emission and the temperature analysis of the casting. Realizing this conception (fig. 2) will enable to develop a process parameter control and consequently to stabilize the casting process. 

The plant is designed to satisfy NSPS requirements. NO emission control is obtained by fuel-rich combustion in the MHD burner and final oxidation of the gas by secondary combustion in the bottoming heat recovery plant. Sulfur removal from MHD combustion gases is combined with seed recovery and necessary processing of recovered seed before recycling. 

Emissions control systems play an important role at most coal-fired power plants. For example, PC-fired plants sited in the United States require some type of sulfur dioxide control system to meet the regulations set forth in the Clean Air Act Amendments of 1990, unless the boiler bums low sulfur coal or benefits from offsets from other highly controlled boilers within a given utiUty system. Flue-gas desulfurization (FGD) is most commonly accomphshed by the appHcation of either dry- or wet-limestone systems. Wet FGD systems, also referred to as wet scmbbers, are the most effective solution for large faciUties. Modem scmbbers can typically produce a saleable waUboard-quaUty gypsum as a by-product of the SO2 control process (see SULFURREMOVAL AND RECOVERY). 

In the early 1970s, air pollution requirements led to the adoption of the double contact or double absorption process, which provides overall conversions of better than 99.7%. The double absorption process employs the principle of intermediate removal of the reaction product, ie, SO, to obtain favorable equiUbria and kinetics in later stages of the reaction. A few single absorption plants are stiU being built in some areas of the world, or where special circumstances exist, but most industriali2ed nations have emission standards that cannot be achieved without utili2ing double absorption or tad-gas scmbbers. A discussion of sulfuric acid plant air emissions, control measures, and emissions calculations can be found in Reference 98. 

Operating parameters include temperature, pressure, oxygen concentration, and residence time. Materials of constmction include stainless steel, nickel, and titanium alloys (the latter for extremely corrosive wastes containing heavy metals). Vented gases from the process may require scmbbing or other emission controls. 

Removal of metal chlorides from the bottoms of the Hquid-phase ethylene chlorination process has been studied (43). A detailed summary of production methods, emissions, emission controls, costs, and impacts of the control measures has been made (44). Residues from this process can also be recovered by evaporation, decomposition at high temperatures, and distillation (45). A review of the by-products produced in the different manufacturing processes has also been performed (46). Several processes have been developed to limit ethylene losses in the inerts purge from an oxychlorination reactor (47,48). 

Once an undesirable material is created, the most widely used approach to exhaust emission control is the appHcation of add-on control devices (6). Eor organic vapors, these devices can be one of two types, combustion or capture. AppHcable combustion devices include thermal iaciaerators (qv), ie, rotary kilns, Hquid injection combusters, fixed hearths, and uidi2ed-bed combustors catalytic oxidi2ation devices flares or boilers/process heaters. Primary appHcable capture devices include condensers, adsorbers, and absorbers, although such techniques as precipitation and membrane filtration ate finding increased appHcation. A comparison of the primary control alternatives is shown in Table 1 (see also Absorption Adsorption Membrane technology). 

NO Emission Control It is preferable to minimize NO formation through control of the mixing, combustion, and heat-transfer processes rather than through postcombustion techniques such as selective catalytic reduction. Four techniques for doing so, illustrated in Fig. 27-15, are air staging, fuel staging, flue-gas recirculation, and lean premixing. 

Process vents and drains, including emission control devices, are often overlooked but are important elements in the safety of batch systems. Inadequate attention to these items can result in incompatible chemical mixtures within the... 

The chemical and metallurgical industries of the world are so varied and extensive that it is impossible to cover all of the processes, emissions, and controls in a single chapter. 

Acid Manufacturing process Air pollutant emissions Control methods in use... 

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