Brief Notes on Removal of Particulate Matter from Bagasse Flue Gases.

William Manso Sept 2007

I.

Introduction:

Scrubbers became a need for bagasse burning boilers in a world where there is an everyday larger concern for atmospheric contamination. These notes aim to introduce what are the particles to be removed from flue gases and the different options at the reach of sugar industry nowadays. No matter how well designed and operated a bagasse fueled boiler is, its flue gases will carry particles or particulate matter (PM) that spreads into the atmosphere. There are three different types of bagasse PM in flue gases from sugar mills: 1. Bagasse Fines: After dried to 0% moisture first step of combustion of wet solid particles-- in the furnace they are carried out by the flue gasses due to too much draft (high velocity), too many fines, poor boiler operations, poor furnace design or other factors. 2. Soot: After bagasse particles completely dry and their volatile matter content is distillated, only fixed carbon and ash remain in flake-shaped soot particles which are carried out by gases. Structurally weak, they easily break into very fine soot powder which is difficult to catch or settle. Soot particles may travel long distances from chimneys before falling down to earth. 3. Fly Ash: If bagasse combustion is complete in the furnace, the mineral content of fiber, sand and other materials which adhere to the cane stalks will produce ash, a fraction of it is collected in the furnace and the rest is entrained by the flue gas. The entrained fraction is called fly ash (FA) and it may settle anywhere inside the boiler along the path of flue gas --due to impingement, changes of direction and low velocity or be spread to the atmosphere.

II.

Efficiency:

In order to meet clean air acts (environmental regulations) and codes there are different types of Precipitators and Scrubbers installed on bagasse burning boilers to remove PM from flue gases. Their efficiency can be measured as a percent of particles separated from those in the gas, equation (1). The efficiency of any scrubber decreases with the size, concentration and density of particles.

100 (1)

Where:

Es; Efficiency of scrubber; Pi , Pf ; Initial & end particle concentration.

III. Ideal scrubber:

An ideal scrubber must: Be of high efficiency; Produce low pressure drop; Require little or no attention; Have little wear and material loss due to erosion and corrosion (for reduced maintenance cost); Require low investment and; Be easy to install and maintain.

Brief Notes on Removal of Particulate Matter from Bagasse Flue Gases.

IV.

Most widely used Devices for the Removal of Particulate Matter from Flue Gases:

4.1. Electrostatic Precipitators:

These electric devices require a substantial amount of electricity to load the PM but have low flue gas pressure drop through them. The initial installation, operation and maintenance costs are higher than any other method of removing PM, also their efficiency is reported to be higher. There are two types: Dry Electrostatic Precipitators (DEP): Reportedly are not suitable for bagasse boilers. Wet Electrostatic Precipitators (WEP): Reported to be successfully in operation and to have high efficiency even if gas is loaded with small sized particles.

4.2. Dry Scrubbers:

By the use of separation techniques the PM are separated from the flue gas and conveyed dry outside the boiler and the scrubber. Most of the time they have exit concentrations above 300mg/Nm3 of PM.

Settling Chambers:

The PM loaded flue gas travels through a large cross section chamber at a velocity lower than the drag velocity of certain sizes of PM. Because of their relatively large size and low efficiency these precipitators are not a good choice.

Inertial separators:

May be wet or dry, they make use of the impingement of particles against different obstacles, baffles or surfaces which cause them to fall. They have low efficiency, high pressure drop and high erosion rates.

Cyclones: Cylindrical bodies with tangential feed of PM loaded flue gas. The gas rotates
and PM are accelerated to the wall falling to a conical section. The efficiency of any type of cyclone is rapidly decrease if there is any air entrance, so, as they are very sensitive to any air tightness failure extreme care has to be taken with their rotary valves or whichever the airlock they utilize. Large equipment at the back of the boiler, the installation of a double cyclone has acceptance because of its simplicity. They have low efficiency and high pressure drop.

Brief Notes on Removal of Particulate Matter from Bagasse Flue Gases.

Multiple Cyclones: These are cyclones installed in parallel inside a

Efficiency and erosive wear increase with decreased cyclone diameter. They are prone to clogs and erosion. Pressure drop is high.

box or housing.

Efficiency ranges from low to mid level normally achieves exit values around 200 300 mg/Nm3.

Filter Bags: (Bag House): Gas passes through a cloth. High efficiencies are reported
for dry non combustible particles. Bagasse may carryover incandescent particles that can start a fire. These separators are difficult to clean and prone to clog.

4.3. Wet Scrubbers:

They combine the separation techniques with the use of water to help catch and carry outside the boiler or the scrubber the dispersed PM. The efficiency increases in relation to the total surface contact between washing water (either a layer or sprayed droplets) and flue gases, 92 to 95% of the water is recirculated while 5 to 10% evaporates to the atmosphere and must be made up. A Wet Scrubber is a part of a system generally composed of: The scrubber itself; Gas ducting from boiler, chamber or scrubber, discharge bins, gas ducting to IDF and supporting structure; Water Injection and Circulation System (pumps, piping, instruments, valves, sprays); Slurry Discharge (ash, soot and water suspension discharged via channels or tubes); Sump and Pump (receive the slurry and send it to cleaning station); Cleaning Station (large size particles are screened and the remainder is treated using clarifiers, settling ponds and returning pumps); Water Storage (tank or pond).

Each system must be designed for each case considering peak loads. It is advisable to avoid the use of slurry pumps whenever possible by using gravity when the difference of level between boilers and settling ponds are adequate.

Brief Notes on Removal of Particulate Matter from Bagasse Flue Gases.

There are different types of wet scrubbers. The most widely used in the sugar industry are the following:

Wet Cyclones:
These are a type of cyclones with a central spray pipe that distributes water. Solid particles are caught by the drops of water which become heavy drops of slurry that separates from the gas at the cyclone due to centrifugal force.

Static Baths:
Flue gas is injected via nozzles through a bed o bath of water. High efficiencies are reported at high gas pressure drop.

Venturi Scrubber:
Flue gas passes at high velocity through a narrow section (reduced cross section). Water is sprayed both before the narrow section to wet the surfaces and improve flow and after it in order to saturate the gas. Venturi scrubbers provide high efficiency but also cause high pressure drop and erosion.

Figure 1: Venturi Scrubber Brief Notes on Removal of Particulate Matter from Bagasse Flue Gases.

Sieve Plate Scrubber:

A gas chamber with a perforated plate (sieve) on top of which a film of water is distributed. Flue gas flows up preventing water from entering the holes. The slurry is discharged to the side. Pressure drop ranges from 60 to 100kg/m2. Exit PM concentration achieved may be less than 100mg/Nm3 of PM under correct design & operation conditions.

Figure 2: Sieve plate scrubber

Spray Tower Scrubber:

Perhaps the simplest method to remove suspended PM, toxins or smelly compounds from a contaminated gas or air flow. Finely sprayed water drops are injected into the gas flow until it is saturated of water. Flue gas loaded with particles is saturated with finely sprayed water, when both water and solids contact each other they form drops of slurry that settle in a chamber where gas is directed upwards at a velocity which permits separation or a demister is installed on top. A particulate load of 150-200mg/Nm3 is relatively easy achieved. Less than 150 mg/Nm3 also is achievable with a well maintained sophisticated spraying system and carefully designed chamber. Pressure drop varies from low to mid (25 to 75kg/m2).

Brief Notes on Removal of Particulate Matter from Bagasse Flue Gases.

Figure 3: Side view drawing of the spray tower wet scrubber installed at a 42,6kg/cm , 400C, 85 t/h boiler designed by Author for La Pastora Sugar Mill in Venezuela. Please note the boiler is on operation.

Figure 4: A boiler, originally 350 60t/h @ 32kg/cm in Molipasa Sugar Mill in Venezuela, was C, redesigned by Author for400C, 85 t/h. The upgrade included the modification of the boiler bank, a new superheater, air heater and economizer (1) as well as the flue gas wet scrubber(2)

email: williammanso@cantv.net & williammanso@gmail.com

Brief Notes on Removal of Particulate Matter from Bagasse Flue Gases.