Dustex Overview for DustexTurkey Training
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Transcript of Dustex Overview for DustexTurkey Training
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Corporate History
Dustex Corporation Dustex was founded in 1947 as a division of American
Precision Industries
Dustex initially entered into the market providingspecialty cyclones for food and chemical processing
Dustex holds 18 APC equipment patents
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Corporate Overview
Dustex Corporation Dustex is incorporated in North Carolina
Privately-held company with ownership active inmanagement and project execution
Dustex maintains three office locations Corporate headquarters located in Kennesaw, Georgia
Automation/Controls/Aftermarket Division located in Acworth,Georgia
Fabrication Division located in Rocky Mount, NC
Captive Fabrication Shop in Kingston, OH
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Dustex Product Lines
Pulse Jet and Reverse air baghouses
Dustex enhanced design pulsejet baghouse withLong Bag technology
Mercury control systems / Activated carbon
injection Sodium Bicarbonate, Trona and Hydrated lime
injection systems Multi-pollutant High Rate Recirculation fluid bed
scrubber systems Multi-clones
Standard products Bin vents
Dust valves
Material handling collectors
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Primary Markets Served
Utility boilers
Industrial / institutional boilers
Biomass and Waste to Energy
Cement and Lime Plants Steel (primary and secondary)
Foundry
Food Processing
Chemical Processing
Aluminum
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Dustex In-House Capabilities
Engineering including Computational Fluid Dynamics
modeling
Fabrication
Design/Build Project Management
Controls and Automation
Commissioning and Aftermarket Support
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Dustex CFD Modeling
Dustex provides 3D flow modeling on critical areas to thescrubber, baghouse and ACI Injection systems
3D solid modeling and flow analysis is performed in-house
Provides improved flow profiles in modules
Improved Cleaning Performance
Reduced potential for bag abrasion
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Dustex Fabric Filters
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Purpose of the Baghouse
The function of thebaghouse is to collect theparticulate waste fromProcess Gas Streams witha high level of efficiency
The baghouse alsoprovides enhancedmercury control withactivated carbon injectionprior to baghouse.
Baghouse aids in HCl and
SO2/SO3 control whencoupled with a dryscrubber
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Baghouse advantages over ESP
Capable of handling large temperature and volume swings.
Higher level of mercury control with lower Carbon
consumption on PAC systems.
Capable of much lower emissions levels.
Does not require pretreatment of gasses to control
particulate.
Generally speaking, baghouses have an overall lower total
lifetime maintenance cost as compared to ESPs. ESPshave a reported high operational upkeep.
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Fabric Filter Design Types
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Reverse Air Filters
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Reverse Air Design
Developed for with large
volumes and large bags
Air flows up through the
inside of the bags wheredust collects
Cleaning is by a reverse
air fan that pushes air
backwards through the
filter
Limited to 2.25:1 gross
A/C
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Reverse Air Design
Designed as a panelized unit
MUST clean offline
Can be Cost effective at volumes Over 1,000,000
acfm (1,700,000 m3/hr) Formerly used in Utility industry, but largely
replaced by pulse jet
Still seen rarely in the Steel industry
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Pulse Jet Baghouse
Inlet Design Comparison
Hopper Entry vs.
Housing Inlet Design, Cross-flow
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Traditional Hopper Entry Design
Developed for use with
short bags (< 18 feet)
Air flow up through bags
inhibits cleaning and leadsto re-entrainment
Can lead to abrasion
problems and high
pressure drop
Used by some suppliers
for long bag designs
Limited to 4:1 A/C
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Typical Hopper Entry Collector
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Traditional
Hopper Entry Ladder Baffle
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Hopper Entry Advantages
The original Pulse Jet filter design
Cost effective at volumes less than 300,000 acfm(500,000 m3/hr)
Commonly supplied with walk in plenum Best design for low volumes where price is the
most critical factor
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New Technology
Housing Inlet Design, Cross-flow
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Side Plenum Design
Single Modules with up to 304 bags
Side Plenum ships loose
Cost effective at volumes up to 500,000 acfm
(850,000 m3/hr) Shop installed Hopper heaters and Insulation with
cladding
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Side Housing Inlet
New technology for longbag design >24 (7.3m)
Flow enters side of moduleand flows across bags
Efficient on-line cleaning athigh A/C ratios
Reduces bag abrasionissues
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Side Plenum Module
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Split Module Design
Single Modules with up to 576 bags
Module ships as two halves with hoppers attached
Cost effective at volumes in excess of 400,000
ACFM (680,000m3/hr) Single Train units up to 2,000,000 ACFM
(3,400,000 m3/hr)
Shop installed insulation and cladding
Can be adapted to panelized design if required forlarge volume
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Split Module Erection
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Design Features
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Dustex Top Door
Monolithic top door withintegrated CleaningSystem allows for easybag access while avoiding
confined space concerns Floating Pan design
provides allows for moduleexpansion without leaking
Intermediate pressurepulse system providesefficient cleaning and longbag life.
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Integral Top DoorBottom View
Showing blow pipes
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Header and Pulse Valve Assy.
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Clean air plenum
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Top of Tube Sheet
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Bag Cleaning
On line vs. Off line
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On-lineCleaning Operation
Dirty Flue gas
from upstream
Flue stream to
ID Fans
DP
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On-lineCleaning Operation
Dirty Flue gas
from upstream
Flue stream to
ID Fans
DP
High DP condition detected
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On-line Cleaning Operation
Dirty Flue gas
from upstream
Flue stream to
ID Fans
Cleans a row of filters
DP
Solenoid valve opens
While one row is being cleaned, the other rows in
the module continue to operate
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On-line Cleaning Operation
Dirty Flue gas
from upstream
Flue stream to
ID Fans
DP
Solenoid valve closes
System starts another
row of bags
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Off-lineCleaning Operation
Dirty Flue gas
from upstream
Flue stream to
ID Fans
DP
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Off-line Cleaning Operation
Dirty Flue
gas from
upstream
Flue stream to
ID Fans
DP
High DP condition detected
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Off-line Cleaning Operation
Dirty Flue
gas from
upstream
Flue stream to
ID Fans
Stop flow in
Module
DP
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Off-lineCleaning Operation
Dirty Flue gas
from upstream
Flue stream to
ID Fans
Clean a row of filters
DP
Solenoid valve opens
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Modern developments in Pulse
Jet Baghouse Technology
CFD Modeling use as a progressive tool fordistribution and inlet development
Cross-Flow Inlet Design contrasted with older hopperentry Cross flow development has allowed for:
more effective cleaning systems
Significant reduction in high velocity streamlining andabrasion
Elimination of can velocity
Increase in Air to Cloth ratios (cloth face velocity) due tomedia effectiveness
Increased filter life
Aid in filter bag length increase
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Additional Modern developments Increase in filter bag length (as long as 10 meters) due to advancements an
testing of cleaning systems in conjunction with cross flow technology Development of long bag technology has allowed a very cost effective option to
reverse air collector with smaller footprint
Modern Long bag technology has allowed pulse collectors with the footprintequal to or smaller than Electrostatic Precipitators, with the added benefit of noemission swings with load swings
Module lift-off door sealing advancements reducing or eliminating air
infiltration which causes corrosion and eliminates confined space issuesthat would be present n a walk-in plenum unit
Filter media developments allowing wider range of applications andefficiency
Control system advancements allowing: Cost effective PLC based cleaning controls (without timer cards)
Cost effective and reliable demand based cleaning which allows for tightbaghouse DP control eliminating Furnace draft swings and helping retainsorbents on the filter media for maximizing HAP reduction particularly forMercury control and dry scrubbing applications
Easier plant wide networking and integration with DCS equipment as well asremote diagnostics options.
PLC based redundancy availability
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Dustex Fabrication
Dustex Fabrication Shop in NCCaptive Shop in OH
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Modularized Utility collector inDustex Fab shop
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Module Half On Jig
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Erection Friendly Designs
Side Plenum and Split Module for
More cost effective field erection
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Side Plenum Erection
E ti Ti li (1 f 3)
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Typical Baghouse Module First Baghouse Module Being Lifted Into Place
First Baghouse Module Being Set In Place First Six (6) Baghouse Modules Set In Place
Erection Timeline (1 of 3)
Erection Timeline (2 f 3)
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Final Six (6) Baghouse Modules Set In Place Baghouse Inlet-Outlet Duct
Baghouse Top Section w/Installed Air Pipe Baghouse Penthouse Steel
Erection Timeline (2 of 3)
E ti Ti li
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Baghouse Penthouse Structural Steel Erection Baghouse Penthouse Structural Steel Erection
Baghouse Penthouse Level (Top of Baghouse El.287-0)
Erection Timeline(3 of 3)
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Baghouse Dynegy Unit 2
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Completed 110MW unit
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Completed 300MW Unit
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Nova Scotia Power
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Activated Carbon Injection
Systems (ACI)
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ApplicableIndustries
Solid Fuel Boilers / Power Generation
Minerals Processing / Cement Plants Municipal Solid Waste Combustion
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Purpose of ACI
Introduce activated carboninto the flue stream toadsorb Mercury andMercury compounds
present in the flue gasses Activated Carbon Can Also
be used for Dioxin/Furancontrol in MSWapplications
Carbon is injected throughan array of injection lancesto insure even distribution
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Dustex ACI Scope
Dual Discharge Silo
Pre-assembled Loss-in-
Weight feed system
Injection lance supplyincluding CFD model
Standalone Control and
Power Panel
Skid Mounted
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ACI systems
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ACI Silo
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Mercury Removal Test Data
1,058,000 ACFM operating at 375 deg F has
tested at 90% mercury reduction with 0.58
#/million ACF injection rate
410,000 ACFM operating at 325 deg F has testedat 90% mercury reduction with 0.75 #/million ACF
injection rate
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Scrubbers for Removal of SOx
and Acid Gases
Three Main Methods of Utility Size Scrubbers
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Three Main Methods of Utility Size Scrubbers
Spray Dryer
Advantages:
Relatively Low Capital cost
Easy for Retrofit applications with existing baghouse
Simplicity
Disadvantages:
Not good for higher than 90% removal efficiencies
Not good for Fuel Flexibility
Lime slurry Equipment present
Very High Maintenance
Three Main Methods of Utility size Scrubbers
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Lime Slurry reagent based Wet Scrubber
Advantages: High Removal efficiency, greater than 90%
Fuel flexibility
Not size limited
Disadvantages: Slurry Based
High horsepower consumption
More equipment hence associated maintenance
Three Main Methods of Utility size Scrubbers
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Circulating dry scrubber
Advantages:
Low Maintenance
Simplicity
High Removal efficiencies, greater than 90%
Relatively Low Capital cost
Fuel Flexibility Scrubbing efficiency higher than spray dryer, Well over
90% removal
Lower operating temperatures with high reagentconcentration allows adsorbsion of Heavy metals
Disadvantages:
Equipment elevation
Requires Multiple trains for units over 300 MW
Dustex High Circulation Rate
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Dustex High Circulation Rate
Dry Fluid Bed Scrubbers HCl, SO2, HF Control
Scrubbing efficiencies >90%
Lower reagent consumption due to recirculation
Lower Maintenance than Spray Dryer or Wet Scrubber Low operating temperature gives side benefit of Heavy
Metals Control
Utility projects over 50 MW executed in conjunction with
Babcock Power
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Operating Principal
Flue Gas Enters bottom of scrubber tower
Fresh Reagent and recirculation from the fabric filter are
added to create desired tower pressure drop
Water Spray cools to 20-30 F above saturation
Carry over material is collected in the fabric filter
baghouse.
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Scrubber Installation
110 MW Installation
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110 MW Installation