Report 3 - Dust and Mist Collection - Landicho, Santos and Virata PDF

PAMANTASAN NG LUNGSOD NG MAYNILA

University of the City of Manila
College of Engineering and Technology
Department of Chemical Engineering
DUST & MIST COLLECTION
SUBMITTED BY:
LANDICHO, Vanessa TWC.
SANTOS, Princess Gabrielle C.
VIRATA, Ma. Patricia S.
SUBMITTED TO:
Engr. April Anne Tigue
CHE 518
PROFESSOR
TABLE OF CONTENTS
DUST COLLECTION 3
Definition and Introduction 3
Sources of Dust 3
Importance of Dust Collection 5
Particulate Matter Control 7
Equipment for Particulate Matter Control 10
MIST COLLECTION 27
Introduction 27
Droplet Formation 27
Performance Characteristics 29
Uses of Mist Eliminators 31
Operation Fundamentals for Various Types of Mist Collectors 31
Measuring Collector Efficiency 35
Common Applications 36
Process Applications 39
Design Equations 40
REFERENCES 41
CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

DUST AND MIST COLLECTION 2
DUST COLLECTION
Airborne particulate matter ranging in diameter from 10 to 50 microns, generated

by activities such as cutting, crushing, detonation, grinding, and handling of organic and
inorganic matter such as coal, grain, metal, ore, rock, wood. Their presence in upper
atmosphere can cause either a net warming or a net cooling effect, depending upon their
surface color. Dust particles with black upper and gray or white lower surface would cause
warming, whereas those with opposite color arrangement would cause cooling. Industrial
dust (generated by cutting, drilling, grinding, or sawing) can pose health risks if inhaled
and (because such particles usually are less than 10 microns in diameter) would be more
hazardous due to its ability to embed deep into lungs and other tissue.
Below is a list of hazardous dusts in the workplace:
• mineral dusts from the extraction and processing of minerals (these often contain
silica, which is particularly dangerous);
• metallic dusts, such as lead and cadmium and their compounds;
• other chemical dusts, such as bulk chemicals and pesticides;
• vegetable dusts, such as wood, flour, cotton and tea, and pollens;
• moulds and spores.
Asbestos is a mineral fiber, which is particularly dangerous, and is found, for

example, in maintenance and demolition of buildings where it had been used as insulation
material.
Sources of Dust
Mineral dusts are generated from parent rocks by any breaking down process, and
vegetable dusts are produced by any dry treatment. The amount, hence the airborne
concentration, is likely to depend on the energy put into the process. Air movement
around, into or out of granular or powdered material will disperse dust. Therefore, handling

methods for bulk materials, such as filling and emptying bags or transferring materials
from one place to another, may constitute appreciable dust sources. Coarse materials
usually have a dust-sized component as a result of attrition. If dust clouds are seen in the
air, it is almost certain that dust of potentially hazardous sizes is present. However, even
if no dust cloud is visible, there may still be dangerous concentrations of dust present with
a particle size invisible to the naked eye under normal lighting conditions.
Unless its generation is prevented or it is removed from the air, dust may move
with ambient air and reach even persons who are remote from the source and whose
exposure is unsuspected.
Damp materials are less likely to release airborne dust, but of course this does not
apply if they dry up later.
Sources of Exposure
• Mining, quarrying, tunneling, stone masonry, construction, and any process which
breaks or separates solid material;
• Foundries and other metallurgical processes, especially the cleaning of casting and
breaking of moulds;
• Any process using abrasive blasting, such removal of paint and rust, cleaning of
buildings and small objects, and etching of glass (N.B., use of sand for these
processes is often unnecessary, and if uncontrolled can cause serious health
impairment, and even fatalities, among the operators, even in a few months);
• Manufacture of glass and ceramics;
• Handling of powdered chemicals in the chemical, pesticide, rubber manufacturing
and pharmaceutical industries;
• Agricultural work involving exposure to soil, intensive animal husbandry, dry
vegetable products, or agro-chemicals;
• Food processing, especially where flour is used;

• Any process involving weighing, bagging, bag-emptying or dry transport of

powdered or friable materials.
Importance of Collection
In certain industries – chemical processing, pharmaceutical, food and agriculture,

metal and woodworking – the air that the people breathe in on a daily basis can be
compromised. Dirt, dust, debris, gasses, and chemicals can be floating around in the air,
causing issues for the employees, as well as the equipment. Dust collectors remove these
contaminants from the air, providing the factory with cleaner air, which can provide
numerous benefits.
The Dangers of Dust
While dust may not seem like a threat to many business owners, much can go awry
without a proper dust collection system. According to OSHA, dust is defined as fine
particles that present an explosion hazard when suspended in the air under certain
conditions. When dust accumulates in produced materials during operations, it can act as
fuel for accidental fires and explosions. Dust is combustible in nature, which makes an
overabundance of dust a major safety hazard in work environments. When you make a
point to invest in an effective dust management system, you’re investing in the prevention
of unwanted fires and explosions in the workplace. Also, proper dust collection and air
filtration is important in any work space. Repeated exposure to wood dust can cause
chronic bronchitis, emphysema, "flu-like" symptoms, and cancer. Wood dust also
frequently contains chemicals and fungi, which can become airborne and lodge deeply in
the lungs, causing illness and damage. Below are the benefits of a dust collection system:
• Improves Health and Safety

When the air is filled with dirt, dust, debris, chemicals or gasses, the lungs of
anyone who breathes this air in is put in jeopardy. Not only that, but these
contaminants can collect on or near equipment, posing a significant fire hazard.

With a dust collector, these contaminants are removed from the air, cleaning the
air and improving the safety of everyone inside.
• Increased Productivity
When dirt, dust and debris collects on equipment, it can make its way inside,
interfering with the mechanics. This can lead to slower machines and broken
equipment. Compromised machinery constantly needs attention and repairs. Dust
collectors remove this risk, allowing your machinery to work at optimal
performance.
• Better Product Quality
With all kinds of contaminants in the air, they can collect on products throughout
the manufacturing process. Chemicals and gasses can seep into your products,
giving them an off odor. These factors can negatively impact the quality of the
finished product. Dust collectors, however, significantly reduce the contaminants
in the air, keeping them away from finished products, improving their quality and
increasing customer satisfaction.
• Meeting Compliance Regulations
There are numerous laws and regulations in place for workplace safety. Some of
these regulations are related to the environment, and the quality of the air. Poor air
quality can cost you heavily, not just in fines, but by harming your employees and
creating potential hazards that can destroy your factory. Dust collectors help you
to comply with governmental regulations, with the added bonus of keeping
everyone (and everything) inside the building safe.
• Satisfied Employees
When the air quality is bad, employees suffer. As a result, they become unhappy,
and start to look for employment elsewhere. Unsatisfied employees don’t work well,
and high employee turnover can cost you big. Keeping the air clean and healthy
with a dust collector improves the morale of your employees, allowing you to retain
great, happy people in the workplace.

Particulate Matter Control
The control of particulate matter is an important aspect of industrial air pollution

engineering. Particles are collected by a combination of several mechanisms. The six
available mechanisms are gravitational settling, centrifugal impaction, inertial impaction,
direct interception, diffusion, and the electrostatic attraction. The physical phenomenon
of gravitational settling, centrifugal impaction and electrostatic attraction are known to
engineers.
A. Gravitational Settling
The gas velocities in the settling chamber must be sufficiently low for the
particles to settle due to gravitational force. Literature indicates that gas velocity
less than about 3 m/s is needed to prevent re-entrainment of the settled
particles. The gas velocity of less than 0.5 m/s will produce good results.
Curtains, rods, baffles and wire mesh screens may be suspended in the
chamber to minimize turbulence and to ensure uniform flow. The pressure drop
through the chamber is usually low and is due to the entrance and exit losses.
B. Inertial Impaction:
The large particles in the gas stream have too much inertia to follow the gas
streamlines around the impactor and are impacted on the impactor surface,
while the small particles and the gas tend to diverge and pass around the
interceptor.
C. Direct Interception:
In case of direct interception, the particles have less inertia and barely follow
the gas streamlines around the fiber. If the distance between the center of the
fiber and the outside of the fiber is less than the particle radius, the particle will
graze or hit the fiber and be "intercepted". Inertial impaction and direct

interception mechanisms account for 99% collection of particles greater than 1

micrometer aerodynamic diameter in fabric filter systems.
D. Diffusion:
In diffusion, small particles are affected by collisions on a molecular level.

Particles less than 0.1 micrometer have individual or random motion. The
particles do not necessarily follow the gas streamlines, but, move randomly
throughout the fluid. This is known as "Brownian Motion". The particles may
have a different velocity than the fluid and at some point could come in contact
with the fiber and be collected.
E. Electrostatic Precipitation
Electrostatic precipitation is a method of dust collection that uses electrostatic
forces, and consists of discharge wires and collecting plates. A high voltage is
applied to the discharge wires to form an electrical field between the wires and
the collecting plates, and ionizes the gas around the discharge wires to supply
ions. When gas that contains an aerosol (dust, mist) flows between the
collecting plates and the discharge wires, the aerosol particles in the gas are
charged by the ions. The Coulomb force caused by the electric field causes the
charged particles to be collected on the collecting plates, and the gas is purified.
This is the principle of electrostatic precipitation, and electrostatic precipitator
apply this principle on an industrial scale. The particles collected on the
collecting plates are removed by methods such as dislodging by rapping the
collecting plates, scraping off with a brush, or washing off with water, and
removing from a hopper.
Agglomeration also contributes to particle collection.
A dust collection system is an air quality improvement system used in industrial,

commercial, and home production shops to improve breathable air quality and safety by

removing particulate matter from the air and environment. Dust collection systems work
on the basic formula of capture, convey and collect.
1. The dust must be captured. This is accomplished with devices such as capture
hoods to catch dust at its source of origin. Many times, the machine producing the
dust will have a port to which a duct can be directly attached.
2. The dust must be conveyed. This is done via a ducting system, properly sized
and manifolded to maintain a consistent minimum air velocity required to keep the
dust in suspension for conveyance to the collection device. A duct of the wrong
size can lead to material settling in the duct system and clogging it.
3. The dust is collected. This is done via a variety of means, depending on the
application and the dust being handled. It can be as simple as a basic pass-through
filter, a cyclonic separator, or an impingement baffle. It can also be as complex as
an electrostatic precipitator, a multistage baghouse, or a chemically treated wet
scrubber or stripping tower.
Types of Systems
Smaller dust collection systems use a single-stage vacuum unit to create suction
and perform air filtration, where the waste material is drawn into an impeller and deposited
into a container such as a bag, barrel, or canister. Air is recirculated into the shop after
passing through a filter to trap smaller particulate.
Larger systems utilize a two-stage system, which separates larger particles from
fine dust using a pre-collection device, such as a cyclone or baffled canister, before
drawing the air through the impeller. Air from these units can then be exhausted outdoors
or filtered and recirculated back into the work space.
Dust collection systems are often part of a larger air quality management program
that also includes large airborne particle filtration units mounted to the ceiling of shop
spaces and mask systems to be worn by workers. Air filtration units are designed to
process large volumes of air to remove fine particles (2 to 10 micrometres) suspended in

the air. Masks are available in a variety of forms, from simple cotton face masks to
elaborate respirators with tanked air — the need for which is determined by the
environment in which the worker is operating.
In industry, round or rectangular ducts are used to prevent buildup of dust in

processing equipment.
Equipment for Particulate Matter Control
Gravity Settling Chamber
This is a simple particulate

collection device using the principle of
gravity to settle the particulate matter
in a gas stream passing through its
long chamber. The primary
requirement of such a device would be
a chamber in which the carrier gas
velocity is reduced so as to allow the
particulate matter to settle out of the moving gas stream under the action of gravity. This
particulate matter is then collected at the bottom of the chamber. The chamber is cleaned
manually to dispose the waste. They are generally used to remove large, abrasive
particles (usually > 50 mm) from gas streams. Since most of the troublesome particles
have much smaller size than 50 mm, there devices are usually used as per cleaners prior
to passing the gas stream through high efficiency collection device.
Settling chambers, which rely on gravitational settling as a collection mechanism,

are the simplest and oldest mechanical collectors. Settling chambers are generally built
in the form of long, horizontal, rectangular chambers with an inlet at one end and an exit
at the side or top of the opposite end.

Flow within the chamber must be uniform and without any macroscopic mixing.
Hoppers are used to collect the settled-out material, though drag scrapers and screw
conveyers have also been employed.
Curtains, rods, baffles and wire mesh screens may be suspended in the chamber to
minimize turbulence and to ensure uniform flow. The pressure drop through the chamber
is usually low and is due to the entrance and exit losses.
The dust removal system must be sealed to prevent air from leaking into the
chamber which increases turbulence, causes dust re-entrainment, and prevents dust from
being properly discharged from the device.
There are two primary types of settling chambers: the expansion chamber and the
multiple-tray chamber.
1. In the expansion chamber, the velocity of the gas stream is significantly reduced
as the gas expands in a large chamber. The reduction in velocity allows larger
particles to settle out of the gas stream
2. A multiple-tray settling chamber is an expansion chamber with a number of thin
trays closely spaced within the chamber, which causes the gas to flow
horizontally between them. While the gas velocity is increased slightly in a
multiple-tray chamber, when compared to a simple expansion chamber, the
collection efficiency generally improves because the particles have a much
shorter distance to fall before they are collected. Multiple-tray settling chambers
have lower volume requirements than expansion-type settling chambers for the
collection of small particles.
The efficiency of settling chambers increases with residence time of the waste gas
in the chamber. Because of this, settling chambers are often operated at the lowest
possible gas velocities.

In reality, the gas velocity must be low enough to prevent dust from becoming re-
entrained, but not so low that the chamber becomes unreasonably large. The size of the
unit is generally driven by the desired gas velocity within the unit, which should be less
than 3 m/s (10 ft/sec), and preferably less than 0.3 m/s (1 ft/sec).
The advantages of settling chambers are:
a. low initial cost,

b. simple construction,
c. low maintenance cost,
d. low pressure drop,
e. dry and continuous disposal of solid particles,
f. use of any material for construction, and
g. temperature and pressure limitations will only depend on the nature of the
construction material.
The disadvantages of this device are:
a. large space requirements and

b. only comparatively large particles (greater than 10 micron) can be collected.
Because of the above advantages and disadvantages, settling chambers are mostly
used as pre-cleaners. They are sometimes used in the process industries, particularly in
the food and metallurgical industries as the first step in dust control. Use of settling
chambers as pre-cleaners can also reduce the maintenance cost of high efficiency control
equipment, which is more subject to abrasive deterioration.
Inertial Separator (Cyclone)
Settling chambers discussed above are not effective in removing small particles.
Therefore, one needs a device that can exert more force than gravity force on the particles
so that they can be removed from the gas stream. Cyclones use centrifugal forces for
removing the fine particles. They are also known as centrifugal or inertial separators.

The cyclone consists of a vertically placed cylinder which has an inverted cone
attached to its base. The particulate laden gas stream enters tangentially at the inlet point
to the cylinder. The velocity of this inlet gas stream is then transformed into a confined
vortex, from which centrifugal forces tend to drive the suspended particles to the walls of
the cyclone. The vortex turns upward after reaching at the bottom of the cylinder in a
narrower inner spiral. The clean gas is removed from a central cylindrical opening at the
top, while the dust particles are collected at the bottom in a storage hopper by gravity.
The efficiency of a cyclone chiefly depends upon the cyclone diameter. For a given
pressure drop, smaller the diameter, greater is the efficiency, because centrifugal action
increases with decreasing radius of rotation. Centrifugal forces employed in modern
designs vary from 5 to 2500 times gravity depending on the diameter of the cyclone.

Cyclone efficiencies are greater than 90% for the particles with the diameter of the order
of 10 µ. For particles with diameter higher than 20 µ, efficiency is about 95%.
The efficiency of a cyclone can be increased by the use of cyclones either in

parallel or in series. A brief explanation of both arrangements is given below:
a. Multiple Cyclones:
A battery of smaller cyclones, operating in parallel, designed for a constant pressure

drop in each chamber. The arrangement is compact, with convenient inlet and outlet
arrangements. They can treat a large gas flow, capturing smaller particles.
b. Cyclones in series:
Two cyclones are used in series. The second cyclone removes the particles that
were not collected in the first cyclone, because of the statistical distribution across the
inlet, or accidental re-entrainment due to eddy currents and re-entrainment in the vortex
core, thus increasing the efficiency.
The advantages of cyclones are:
a. low initial cost,

b. simple in construction and operation,
c. low pressure drop,
d. low maintenance requirements,
e. continuous disposal of solid particulate matter, and
f. use of any material in their construction that can withstand the temperature and
pressure requirements.
The disadvantages of cyclones include:
a. low collection efficiency for particles below 5 - 10 µ in diameter,

b. severe abrasion problems can occur during the striking of particles on the walls
of the cyclone, and

c. a decrease in efficiency at low particulate concentration.
Typical applications of cyclones are:
a. For the control of gas borne particulate matter in industrial operations such as
cement manufacture, food and beverage, mineral processing and textile
industries.
b. To separate dust in the disintegration operations, such as rock crushing, ore
handling and sand conditioning in industries.
c. To recover catalyst dusts in the petroleum industry.
d. To reduce the fly ash emissions.
The operating problems are:
a. Erosion: Heavy, hard, sharp edged particles, in a high concentration, moving at a

high velocity in the cyclone, continuously scrape against the wall and can erode
the metallic surface.
b. Corrosion: If the cyclone is operating below the condensation point, and if reactive
gases are present in the gas stream, then corrosion problems can occur. Thus the
product should be kept above the dew point or a stainless steel alloy should be
used.
c. Build - up: A dust cake builds up on the cyclone walls, especially around the vortex
finder, at the ends of any internal vanes, and especially if the dust is hygroscopic.
It can be a severe problem.

FABRIC FILTER (BAGHOUSE FILTER)
Fabric filter is an air pollution control device and dust collector that removes
particulates or gas released from commercial processes out of the air. It is capable of
high-efficiency particulate matter removal in a wide variety of industrial applications.
The particle size range that this device can collect ranges from 0.1 – 1,000 mm. It has
a high particle collection efficiency due to two reasons:
a. the multiple opportunities for a particle to be captured as it attempts to pass through

a dust cake and fabric
The filter media will accumulate solid particles until a dust cake forms. Once
a dust cake has formed, given the proper media and conditions, the discharged air
or gas will be particle free, within acceptable tolerance. The cake is a barrier with
tortuous pores that trap particles as they travel through the cake. (differences in
pore size and path lengths). The filter cake is a source of increasing pressure drop
(ΔP). Therefore, it has to be removed either at an upper pressure drop limit (ΔP max).
When a pressure drop limits the amount of air passing through the filter
bags, discharge knocks dust from the bags and into a hopper under the collector
for disposal or storage.
b. the multiple modes of particle capture that occur within the dust cake and fabric
i. Impaction
Dust particles strike the fibers placed perpendicular to the gas-flow
direction instead of changing direction with the gas stream.

ii. Brownian Movement

Particles less than 0.1 micrometer have
individual or random motion. The particles do
not necessarily follow the gas streamlines, but, move randomly throughout the fluid.
The particles may have a different velocity than the fluid and at some point, could
come in contact with the fiber and be collected.
TYPES OF BAGHOUSES:
Pulse Jet Fabric Filters
Pulse jet fabric filters, invented during the early 1960s, are used for a wide
variety of small-to-medium size industrial applications. The baghouses are termed
pulse jet since a pulse of compressed air is used for cleaning each of the bags. A
portion of the dust must occasionally be removed from the bags in order to avoid
excessively high gas flow resistances. The bags are cleaned by introducing a high-
pressure pulse of compressed air at the top of each bag. Since the duration of the
compressed-air burst is short (0.1s), it acts as a rapidly moving air bubble, traveling
through the entire length of the bag. This cracks the dust cake on the outside of the
bags and causes some of the dust to fall into the hopper. Cleaning is normally
performed on a row-by-row basis while the baghouse is operating.
The compressed air at pressures from 60 to 90 pounds per square inch gauge
(20 to 40 psig compressed air is used in low pressure-high volume designs) is
generated by an air compressor and stored temporarily in the compressed air
manifold. When the pilot valve (a standard solenoid valve) is opened by the
controller, the diaphragm valve connected to the pilot valve opens suddenly. This
lets compressed air into the delivery tube that services a row of bags. There are
holes in the delivery tube above each bag. The cleaning system controller can
operate on the basis of a differential pressure sensor (static pressure drop), or it can
simply be operated on a timer. In either case, bags are cleaned on a relatively
frequent basis with each row being cleaned from once every five minutes to once

every several hours. Cleaning usually starts with the first row of bags and continues
through the remaining rows in the order the bags are mounted.
Reverse Air Fabric Filters

Reverse air fabric filters
must be compartmentalized.
During cleaning, the gas flow
through a compartment is
stopped, and filtered gas is
passed in a reverse direction
through the bags in the
compartment.

This cleaning procedure is the basis for the name "reverse

air." During the filtering mode, the compartment's outlet and
inlet gas dampers are open. When it is time to clean the
compartment, the outlet damper is closed to block gas flow.
After a short time to allow the bags to relax, the reverse air
damper located near the top of the compartment is opened to
permit filtered gas from the baghouse outlet to be recycled
through the compartment. This reverse flow is sustained for as
little as 30 seconds or as long as several minutes. During this
time, large clumps of dust cake from the interior of the bags are
dislodged and fall by gravity into the hopper.
Reverse air bags are hung from support frames near the tops of the compartments.
The bags are tensioned to 60 to 120 pounds force by spring assemblies on the top frame.
Reverse air bags do not have support cages. Instead, they have a set of anti-collapse
rings sewn into the bags to prevent them from flattening during cleaning.
Mechanical Shaker
A shaker baghouse cleans the bags by mechanically shaking them. The bags
usually hang from the top of the unit and attach to the tube sheet at the bottom. In this
type of system, air typically enters from the bottom. The system pulls the air through to
collect dust on the inside of the bags. Clean air then exits at the top while collected dust
remains inside of the bags.

To clean the bags, the airflow must first be shut off. Then
the hanging mechanism shakes the bags to get rid of the dust,
which drops out the bottom. Vibration produced by a motor-
driven shaft and cam creates waves in the bags to shake off the
dust cake.
Shaker baghouses range in size from small, handshaker
devices to large, compartmentalized units. They can operate
intermittently or continuously. Intermittent units can be used
when processes operate on a batch basis; when a batch is completed, the baghouse can
be cleaned. Continuous processes use compartmentalized baghouses; when one
compartment is being cleaned, the airflow can be diverted to other compartments.
TYPES OF FABRIC FILTERS: ADVANTAGES AND DISADVANTAGES
TYPE ADVANTAGES DISADVANTAGES
Restricted to low
High collection efficiency
MECHANICAL temperatures
SHAKER Strong woven bags Larger space required
Easy operation Frequent maintenance
Unable to remove residual
dust buildup
REVERSE AIR
Preferred for high
Frequent maintenance
temperatures
Restricted to low to medium
temperatures
Unable to function with high
Aggressive cleaning action
PULSE JET humidity gases
Continuous
Smaller space required

ELECTROSTATIC PRECIPITATORS
Electrostatic precipitators (ESP) are

particulate collection devices that use
electrostatic force to remove the
particles less than 5 micron in diameter.
The principle behind is to give
electrostatic charge to particles in a given gas stream and then pass the particles through
an electrostatic field that drives them to a collecting electrode, lose their charge and are
removed mechanically by rapping, vibration, or washing to a hopper below. The Coulomb
force caused by the electric field causes the charged particles to be collected on the
collecting plates, and the gas is purified.
There are three basic steps to particulate matter collection.
✓ Step 1 is the electrical charging and migration of particles towards collection

surface.
✓ Step 2 involves the gravity settling of the collected material from the collection
surfaces.
✓ Step 3 is the removal of the accumulated solids or liquids from the hopper or sump
below the electrically energized zone.
• Dry, negative corona

A dry, negative corona
electrostatic precipitator consists of
a large number of parallel gas
passages with discharge electrodes
mounted in the center and grounded
collection surfaces called plates on
either side. The discharge
electrodes are spaced 4.5 to 6 in.
away from each of the collection

plates. A high negative voltage is applied to

the discharge electrodes. The voltage
difference between the discharge electrodes
and plates creates continuous electrical
discharges termed coronas.
Negatively charged gas ions formed in and
near the corona discharge impart an electrical
charge to the particles and cause them to
move toward the electrically grounded
collection plates. Mechanical hammers called
rappers are used to remove a portion of the
dust layer accumulating on these plates and the small quantities of dust that also
collect on the discharge electrodes. Particle agglomerates and dust layer sheets fall
by gravity into the hoppers during rapping.
Dry, negative corona units are used in large industrial facilities such as cement
kilns, kraft pulp mills, and coal-fired utility boilers. They are termed "dry" because the
collected solids are removed from the collection plates as a dry material. The term
"negative corona" means that the particles are collected by forcing them to move from
a high negatively charged area to an electrically grounded collection plate.
ELECTROSTATIC PRECIPITATOR ADVANTAGES AND DISADVANTAGES

ADVANTAGES DISADVANTAGES
High collection efficiency. High initial cost.
Particles as small as 0.1 micron can Space requirement is more because of
be removed. the large size of the equipment.
Possible explosion hazards during
Low maintenance and operating cost. collection of combustible gases or
particulate

Low pressure drop (0.25-1.25 cm of

water).
Precautions are necessary to maintain
Satisfactory handling of a large
safety during operation. Proper gas
volume of high temperature gas.
flow distribution, particulate
Treatment time is negligible (0.1-10s).
conductivity and corona spark over
Cleaning is easy by removing the units
rate must be carefully maintained.
of precipitator from operation.
PARTICULATE WET SCRUBBERS
Particulate wet scrubbers are a diverse set of control devices. Simple devices,
such as spray tower scrubbers, are used for the collection of particulate matter larger than
approximately 5 µm. Various scrubbing systems, such as tray tower scrubbers,
mechanically aided scrubbers, and wet ionizing scrubbers, are used to collect particulate
matter as small as 1 µm. Scrubbing systems, such as adjustable throat venturis and
condensation scrubbers, are used for high efficiency collection of particulate matter, even
in the < 1 mm size range.

A liquid – usually water – is injected into the waste gas stream. Greater contact of
the gas and liquid streams yields higher dust removal efficiency. The liquid droplets
impact and entrain particulates from the waste gas stream and collecting them in the
sump for blowdown. The treated air stream is discharged through the exhaust stack.
Particulate matter wet scrubbers, like electrostatic precipitators and fabric filters,
use a three-step process for the treatment of particulate-laden gas streams.
1. Particle capture in either droplets, liquid sheets, or liquid jets

2. Capture of the liquid droplets entrained in the gas stream
3. Removal and treatment of the particulate matter-contaminated liquid prior
to discharge
Particle capture is accomplished in a contacting vessel, such as a venturi scrubber,
a tray tower scrubber, or a spray tower scrubber. Mist eliminators built into the scrubber
vessel or a separate vessel are used to collect the entrained water droplets after the
scrubber. Clarifiers, vacuum filters, and/or settling ponds are often used to treat the waste
stream from the scrubber.
The particle and the liquid come in contact through four different mechanisms:
a) Inertial impaction - When water droplets placed in the path of a dust-laden gas
stream, the stream separates and flows around them. Due to inertia, the larger
dust particles will continue on in a straight path, hit the droplets, and become
encapsulated.
b) Interception - Finer particles moving within a gas stream do not hit droplets directly
but brush against and adhere to them.
c) Diffusion - When liquid droplets are scattered
among dust particles, the particles are
deposited on the droplet surfaces by
Brownian movement, or diffusion. This is the
principal mechanism in the collection of
submicrometer dust particles.

d) Condensation nucleation - If a gas passing through a scrubber is cooled below the

dewpoint, condensation of moisture occurs on the dust particles. This increase in
particle size makes collection easier.
WET SCRUBBER ADVANTAGES AND DISADVANTAGES
ADVANTAGES DISADVANTAGES
Small space requirements Corrosion problems
No secondary dust sources High power requirements
Handles high-temperature, high-
Water pollution problems
humidity gas streams
Minimal fire and explosion hazards Difficult dust recovery
Ability to collect both gases and
particulate matter
SELECTING A DUST COLLECTOR
Dust collectors vary widely in design, operation, effectiveness, space requirements,

construction, and capital, operating, and maintenance costs. Each type has advantages
and disadvantages. However, the selection of a dust collector should be based on the
following general factors:
▪ Dust concentration and particle size – For minerals

processing operations, the dust concentration can
range from 0.1 to 5.0 grains (0.32 g) of dust per
cubic foot of air (0.23 to 11.44 grams per cubic
meter), and the particle size can vary from 0.5 to
100 micrometers (µm) in diameter.

▪ Degree of dust collection required – The degree

of dust collection required depends on its potential
as a health hazard or public nuisance, the plant
location, the allowable emission rate, the nature of
the dust, its salvage value, and so forth. The
selection of a collector should be based on the
efficiency required and should consider the need for high-efficiency, high-cost
equipment, such as electrostatic precipitators; high-efficiency, moderate-cost
equipment, such as baghouses or wet scrubbers; or lower cost, primary units, such
as dry centrifugal collectors.
▪ Characteristics of airstream – The characteristics of the airstream can have a
significant impact on collector selection. For example, cotton fabric filters cannot
be used where air temperatures exceed 180 °F (82 °C). Also, condensation of
steam or water vapor can blind bags. Various chemicals can attack fabric or metal
and cause corrosion in wet scrubbers.
▪ Characteristics of dust – Moderate to heavy concentrations of many dusts (such
as dust from silica sand or metal ores) can be abrasive to dry centrifugal collectors.
Hygroscopic material can blind bag collectors. Sticky material can adhere to
collector elements and plug passages. Some particle sizes and shapes may rule
out certain types of fabric collectors. The combustible nature of many fine materials
rules out the use of electrostatic precipitators.
▪ Methods of disposal – Methods of dust removal and disposal vary with the material,
plant process, volume, and type of collector used. Collectors can unload
continuously or in batches. Dry materials can create
secondary dust problems during unloading and
disposal that do not occur with wet collectors. Disposal
of wet slurry or sludge can be an additional material-
handling problem; sewer or water pollution problems
can result if wastewater is not treated properly.

MIST COLLECTION
Mist can generally be defined as a liquid droplet 20 microns in diameter or smaller.
In any process where gas and liquid come into contact, the gas will entrain some amount
of the liquid droplets. This entrainment can cause process inefficiencies, product loss,
and equipment damage. Mist elimination, or the removal of entrained liquid droplets from
a vapor stream, is one of the most commonly encountered processes regardless of unit
operation. Unfortunately, mist eliminators are often considered commodity items and are
specified without attention to available technologies and design approaches
Lubricants and coolants are employed in many applications including metal

cutting, metal forming, grinding, parts washing, and others. For example, milling and
turning operations using water-soluble metalworking fluids typically produce mist droplets
that range from 2 microns to 20 microns. The same operations using oil-based fluids
typically produce mist droplets that range from 0.5 microns to 10 microns.
Some manufacturers believe if they can‘t see the mist, it doesn‘t exist. This view
does not acknowledge the damage submicron mist can do to the manufacturing
environment, in terms of worker exposure, maintenance and housekeeping, and
compliance with indoor air quality or emissions standards. In fact, the human eye cannot
see individual droplets smaller than 40 microns, but there is substantial evidence smaller
mist droplets are present in many metalworking operations. You may not be able to see
them, but you can smell them!
Droplet Formation
The way that droplets are formed determines the size of droplets to be removed.
Knowledge of the mechanisms that cause droplet formation and the resulting droplet size
is essential to proper mist eliminator selection and design.
Entrainment can be generated by the following mechanisms: Mechanical action,

Chemical reaction, Condensation. The figure below illustrates the typical particle size

distribution caused by various mechanisms. Combining this knowledge with experience,

the droplet sizes produced can often be estimated with reasonable accuracy.
Mechanical: Experience shows that droplets generated by mechanical means are

commonly 5-10μ and larger in diameter. But a boiling or bubbling liquid surface will form
droplets down to just a few microns in diameter.
Chemical Reaction: When two gases react to form a liquid product, large
quantities of submicron droplets are formed, which, in turn, requires high efficiency
separation equipment.
Condensation: Entrainment swept off the surface of heat exchanger tubes

consists mostly of large (50+ microns) droplets. However, extremely fine submicron
entrainment is often generated when a liquid condenses directly in the vapor phase due
to cooling of a saturated vapor. This type of very fine entrainment can be seen when
lubricating oil in a compressor is locally heated and vaporized and then quickly condensed
causing a ―blue smoke.

Performance Characteristics
A mist collector‘s major function is to remove mist and smoke droplets from the filtered
airstream. To accomplish this task, a collector must coalesce small drops into larger ones,
and then drain the collected coolant from the filters before they plug. The performance of
a mist collector can be characterized by three measurable properties:
Pressure Drop: The operating pressure drop of the collector is important as part of the
energy cost equation. Higher pressure drops mean more energy is required to pull the
required airflow through the collector.
Efficiency: The efficiency of the collector in removing mist and smoke droplets from the
airstream is important because it determines how clean the air will be as it leaves the
collector and is typically vented to the indoor environment. This is the reason to install a
mist collector – to clean the air. Efficiency is the key measure for how much cleaner the
air will be as it leaves the collector.
Flow Rate: The flow rate of the collector is important because it determines how much
air will be cleaned. If the flow is too low, then less mist–or smoke–laden air will be pulled
through the collector and captured by the system intended to capture it. If the flow rate is
too high, then energy is wasted as surplus air is pulled through the collector. A constant
airflow rate is also desirable for maintaining consistent droplet capture efficiency.
In addition to the basic design of the collector, there are a number of mist properties that
will affect the performance of a mist collector:
▪ Mist concentration – the amount of mist contained in a volume of air varies widely
from application to application. Measured mist concentrations as low as 3 mg/m 3
and as high as 37 mg/m3 have been observed in field testing. It is likely actual
applications have an even larger range of mist concentrations. OSHA limits for
airborne metalworking fluids vary – from 5 mg/ m3 (8-hour exposure) for mineral
oil, to 15 mg/ m3 (8-hour exposure) for other coolants. In a general office

environment, particulate matter concentrations tend to be in the range of 0.02 –

0.03 mg/m3 - substantially lower than mist concentrations near metalworking
operations.
▪ Mist temperature – condensation can occur as high temperature mist cools, which
can affect droplet size and means of collection. For water based coolants, the
water will evaporate at higher temperatures and lower relative humidity levels, thus
creating smaller droplet sizes. Filter media operating temperature limits are also
important to consider when selecting a mist or smoke collection technology.
▪ Type of mist – different types of mist droplets will have different surface tension
and viscosity properties, which impact a mist collector‘s ability to coalesce and
drain the mist.
▪ Mist droplet size distribution – in general it is easier to capture larger droplet
sizes, but large droplets also can be a significant contributor to the overall mass of
liquid contained in the mist, which must eventually drain from the collector. The
Figure shows a hypothetical mist and smoke droplet size distribution.
▪ Inclusions – if a mist is clean, it does not contain dry particles and we only need
to be concerned about coalescing, and draining the liquid. However, a dirty mist
will also contain a fraction of dry particles (swarf) that must also be separated from
the airstream.

Uses of Mist Eliminators
Reduce loss of valuable chemicals: Mist eliminators markedly cut glycol, amine, or
solvent consumption in absorption and regeneration towers.
Increase throughput capacity: Mist eliminators allow a significant increase in

throughput anywhere gases and liquids come into contact in process equipment.
Improve product purity: Mist eliminators prevent contamination of side draws and
overheads in refinery atmospheric and vacuum towers and other distillation columns.
Minimize contamination: Mist eliminators can prevent the poisoning of expensive

downstream catalysts or provide boiler feed water quality condensate from evaporator
overheads.
Provide equipment protection: Mist eliminators protect turbine, blower, and

compressor blades, which can eliminate serious maintenance problems.
Reduce air pollution: Mist eliminators help diminish droplet emissions to

environmentally acceptable levels.
Operation Fundamentals for Various Types of Mist Collectors
Mist droplets can be captured in several ways.
Electrostatic Precipitation

Electrostatic precipitators work by drawing the mist-laden air through an ionizer

that gives each droplet either a positive or a negative charge. The charged droplets are
then captured by collection cells that utilize alternating high voltage and grounded plates
to push/pull the charged droplets onto the plate. The droplets coalesce on the plates and
drain out of the collector.
Electrostatic precipitators have a number of advantages, including no filters to

replace, relatively low energy usage, and high efficiency when new and fully cleaned.
However, electrostatic precipitators have fallen out of favor due to their very arduous and
frequent maintenance requirements. The parts inside an electrostatic precipitator need to
be kept meticulously clean in order to maintain the efficiency of charging and capturing
the droplets. Even with regular maintenance, there can be additional difficulties. Any
damage to the charged plates in the collection cell can result in electric arcs. Similarly,
applications where there is metal dust, chips, or swarf collected with the mist droplets can
result in electric arcs inside the electrostatic precipitator. Finally, electrostatic precipitators
generate ozone, which is an indoor air pollutant and known irritant.
Inertial Separation

Collectors that rely primarily on inertial separation operate in the following way to
separate droplets carried in an airstream. As the airstream is diverted around a surface,
the droplets have momentum and continue on their path, impacting the surface and
ultimately coalescing with other droplets and draining.
Although there are many different types and styles of inertial separation, all have
a few things in common. First, inertial separators can work without a barrier filtration
mechanism – they typically do not have primary filters that would need to be changed.
However, they generally do require fairly regular maintenance to clean the components
of any contamination. Additionally, inertial separation works better on large drops since
the capture of the droplets depends on them NOT following the airstream. Larger drops
have more mass, more momentum, and an increased tendency to impact the capture
surface. Inertial separators tend to have poor efficiency for droplets smaller than 1-2
microns in diameter.
Finally, for powered inertial separators that spin, solid matter can collect and get
stuck in the spinning parts, which will eventually lead to an out-of-balance condition that
transmits vibration to the machine tool and can affect tolerances on machined parts.
Filter Media
Collectors that use fibrous filter media rely on four filtration mechanisms to remove
mist and smoke droplets from an airstream:

1. Sieving is the predominant filtration mechanism collecting larger droplets, greater

than 10 micron. Sieving occurs when the droplet is physically too large to pass
between two or more fibers. Sieving is what stops a flying insect from going through
a window screen. When the droplet contacts a fiber it adheres to the surface,
coalesces with other droplets, and drains from the collector.
2. Inertial impaction is the filtration mechanism collecting mostly micron-sized
droplets and larger. Inertial impaction occurs as the airstream is displaced by the
media fiber while the droplet continues on its original course because of its mass.
3. Interception is the filtration mechanism collecting predominantly 0.1 to 1 micron
size droplets. Interception occurs when a droplet follows an airstream but still
comes close enough to a fiber to adhere to it.
4. Diffusion is the filtration mechanism predominantly collecting very fine droplets,
less than 0.1 micron in size. Because the droplets are so small, they are influenced
by molecular forces within the airstream, which cause the droplets to move in the
same general direction as the airstream and yet move independent of it.
Once droplets adhere to the fibers in the filter media, they coalesce with other droplets
on the fibers. When the coalesced droplet is big enough, the force of gravity will pull the
droplet down along the fiber where it will drain.
One of the big trade-offs in mist filtration is balancing the need for droplets to drain
with the need for high efficiency. Higher filtration efficiencies can be achieved through the
use of smaller fibers. But smaller fibers require resins to hold the media together, and
resins prevent coalesced liquid from effectively draining. Filter media made from small
fibers, tend to plug up easily with captured liquid. When filter media is made from large
fibers, the draining characteristics are vastly improved, but the ability of the media to
capture mist droplets (especially smaller ones) is severely compromised.

Measuring Collector Efficiency
Another interesting point about mist collection that use media filters is that the
pressure drop characteristics are very different from dry particle collectors. Dry particles
in a static (non-cleaning) collector are captured on filters, which cause the pressure drop
to increase substantially, and the efficiency to increase the longer the collector runs.
Essentially, new dry particles have to pass through a cake of previously-captured dry
particles. The dust that is captured serves to increase the particulate efficiency of the
collector.
In mist filtration, the pressure drop will rise modestly as the media becomes
saturated with liquid. However, the efficiency generally suffers a small decline as the
collector continues to run. The underlying reason for the decline in efficiency is the pore
structure created by the fibrous media in a mist filter. As liquid is captured and coalesced,
the small pores filled up, or become plugged, with liquid. The remaining larger pores are
left to do all the filtering – which leads to two things:
1. An increase in air velocity through the remaining pores and an accompanying

increased pressure drop, and
2. An increase in air velocity though the remaining larger pores, which are less
efficient at capturing submicron droplets, so there is an apparent reduction in the
filter‘s efficiency.
If the stated efficiency of the collector is provided for a new filter, it will be higher than
the realized efficiency in the actual application. The only true and representative efficiency
is one measured, using a mist, over a period of time.

Common Applications
Knockout Drums
Designing knockout drums to include mist eliminators will reduce capital

equipment costs and improve efficiency. Knockout drums relying solely on gravity settling
remove only drops larger than 100 microns. Using an efficient mist eliminator will prevent
entrainment of all drops larger than 5 to 10 microns.
This higher efficiency reduces product loss; downstream corrosion; contamination;

and damage to equipment such as compressors, molecular sieve driers, and blowers.
Vessel weights can easily be reduced to half, and handling of liquid slugs is improved.
Evaporators

Customized mist eliminators reduce carryover of dissolved and undissolved solids

to obtain specified steam condensate purity levels below 1 to 50 ppm. This not only
prevents product loss, but it also protects compressor internals in vapor recompression
systems, provides boiler feed water quality condensate, and prevents potential pollution
problems.
Industrial installations vary from chemical plants (caustic and inorganic chemical
concentrators), to pulp and paper (black liquor and pulping chemical recovery), to the
food industry (sugar, salt, and corn syrup production).
Steam Drums
Customized mist eliminators reduce carryover of dissolved solids to obtain

specified steam condensate purity levels from 1 ppm down to 5 ppb without the need for
external separator vessels. Operating pressures can range from 20 to > 2500 psig [1 to
170 bar].

Distillation Towers
Liquid entrainment can cause performance problems and

limit capacity in packed and trayed distillation towers in two
ways.
▪ At intermediate draw-off trays, entrainment from

below reduces product purity and can allow nonvolatile
contaminants into the draw-off liquid.
▪ The overhead gas product can also be
contaminated with liquid entrainment.
In both cases, the problem is often misinterpreted as a problem with the trays or
packing. In reality, it is a problem of entrainment, which can be solved by a properly
designed mist eliminator.
Scrubbers
From clean gas scrubbers and process vents to fouling services, such as flue gas
desulfurization (FGD) systems or steel mill blast furnace exhausts, mist eliminators help
improve efficiency and capacity.

Process Applications
Refineries
Mist eliminators in fractionators increase throughput capacity and

allow deeper cuts for greater yields.
• In atmospheric and vacuum pipestills, reduced
entrainment from the wash oil zones allows deeper cuts
and greater throughput.
• In downstream crackers and reformers, mist eliminators
prolong catalyst life by reducing carbon and metals in side
draws.
Petrochemical Plants
Mist eliminators are used in the interstage knock-out drums of the compressor
trains to extend compressor run length and service life. They are also used in quench
towers to prevent contamination and protect downstream equipment.
Gas Absorption Systems
Designers and operators of gas absorption systems use glycols, amines, and other
proprietary solvents to remove water vapor, H2S, CO2 , or other contaminants from gas
streams. However, they often follow equipment specifications that have not been
optimized
to minimize losses of these expensive chemicals. Losses can result from several
causes, including the following:
▪ Carryover losses of absorption chemicals with the treated gas.

▪ Entrainment losses in the overhead gas from the regeneration towers.
▪ Foaming resulting from liquid hydrocarbon entrainment into the absorber.

Sulfuric Acid Plants
Well-engineered mist eliminators are critical to the cost-effective operation of every

sulfuric acid plant. In the drying, intermediate, and final absorption towers, poorly
performing mist eliminators contribute to corrosion of ducting, blowers, heat exchangers,
and vessels. Stack emissions can result in environmental non-compliance, fines, and
potential closure.
Design Equations
To determine mist eliminator cross-sectional area (and hence vessel size) and
predict performance in terms of removal efficiency, the optimum design gas velocity is
determined first. The Souders-Brown equation is used to determine this velocity based
on the physical properties of the liquid droplets and carrying vapor:

REFERENCES
Retrieved from https://www.business.qld.gov.au/industries/mining-energy-
water/resources/safety-health/mining/hazards/dust/sources
Retrieved from https://www.who.int/occupational_health/publications/airdust/en/
Retrieved from https://saferenvironment.wordpress.com/2009/09/05/industrial-dust-air-
pollution-and-related-occupational-diseases/
Retrieved from https://biscoair.com/blog/the-importance-of-dust-collection-for-your-
business/
Retrieved from https://macyindustries.com/dust-collection/
Retrieved from https://www.actdustcollectors.com/blog/the-importance-of-dust-
collectors-19451
Retrieved from https://www.spiralmfg.com/wp-
content/uploads/2015/09/dust_collection.pdf
Retrieved from https://en.wikipedia.org/wiki/Dust
Retrieved from https://en.wikipedia.org/wiki/Dust_collection_system
Retrieved from https://en.wikipedia.org/wiki/Dust_collector
Retrieved from http://www.eng.utoledo.edu/~akumar/IAP1/Pollution%20Control.htm
Retrieved from http://www.eng.utoledo.edu/aprg/courses/iap/text/part_ctrl1.html
Retrieved from http://www.shareyouressays.com/knowledge/useful-notes-on-the-
gravitational-settling-chamber-important-air-pollution-control-equipment/114112
Retrieved from https://www.donaldson.com/en-be/industrial-dust-fume-mist/technical-
articles/mist-collection-fundamentals-applications/


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PAMANTASAN NG LUNGSOD NG MAYNILA

PAMANTASAN NG LUNGSOD NG MAYNILA

DUST & MIST COLLECTION

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

Airborne particulate matter ranging in diameter from 10 to 50 microns, generated

Below is a list of hazardous dusts in the workplace:

Asbestos is a mineral fiber, which is particularly dangerous, and is found, for

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

• Any process involving weighing, bagging, bag-emptying or dry transport of

In certain industries – chemical processing, pharmaceutical, food and agriculture,

The Dangers of Dust

• Improves Health and Safety

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

Particulate Matter Control

The control of particulate matter is an important aspect of industrial air pollution

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

interception mechanisms account for 99% collection of particles greater than 1

In diffusion, small particles are affected by collisions on a molecular level.

Agglomeration also contributes to particle collection.

A dust collection system is an air quality improvement system used in industrial,

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

In industry, round or rectangular ducts are used to prevent buildup of dust in

Equipment for Particulate Matter Control

Gravity Settling Chamber

This is a simple particulate

Settling chambers, which rely on gravitational settling as a collection mechanism,

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

The advantages of settling chambers are:

a. low initial cost,

The disadvantages of this device are:

a. large space requirements and

Inertial Separator (Cyclone)

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

The efficiency of a cyclone can be increased by the use of cyclones either in

A battery of smaller cyclones, operating in parallel, designed for a constant pressure

The advantages of cyclones are:

a. low initial cost,

The disadvantages of cyclones include:

a. low collection efficiency for particles below 5 - 10 µ in diameter,

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

c. a decrease in efficiency at low particulate concentration.

Typical applications of cyclones are:

The operating problems are:

a. Erosion: Heavy, hard, sharp edged particles, in a high concentration, moving at a

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

FABRIC FILTER (BAGHOUSE FILTER)

a. the multiple opportunities for a particle to be captured as it attempts to pass through

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

ii. Brownian Movement

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

Reverse Air Fabric Filters

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

This cleaning procedure is the basis for the name "reverse

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

Smaller space required

CHE : INTRODUCTION TO PARTICLE TECHNOLOGY

Electrostatic precipitators (ESP) are

There are three basic steps to particulate matter collection.