Emission Control from Industrial Boilers

204 Pages·1995·17.861 MB·\204

by  John T. Quigley (Author), Frank L. Cross Jr. (Author), Howard D. Hesketh (Author)

EMISSION CONTROL FROM
INDUSTRIAL BOILERS

EMISSION
CONTROL FROM
INDUSTRIAL
BOILERS
Edited by
HOWARD E. HESKETH, Ph.D., P.E., D.E.E.
Consultant/ Professor
Southern Illinois University, Carbondale, IL
FRANK L. CROSS, JR., P.E., D.E.E.
Consultant
Harding Lawson Associates, Orlando, FL
JOHN T. QUIGLEY, Ph.D., P.E., D.E.E.
Professor
University of Wisconsin, Madison, WI
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
Emission Control from Industrial Boilers
First published 1995 by Technomic Publishing Company, Inc.
Published 2018 by CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 1995 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
ISBN 13: 978-1-56676-182-6 (hbk)
This book contains information obtained from authentic and highly regarded sources.
Reasonable efforts have been made to publish reliable data and information, but the author
and publisher cannot assume responsibility for the validity of all materials or the
consequences of their use. The authors and publishers have attempted to trace the copyright
holders of all material reproduced in this publication and apologize to copyright holders if
permission to publish in this form has not been obtained. If any copyright material has not
been acknowledged please write and let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted,
reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other
means, now known or hereafter invented, including photocopying, microfilming, and
recording, or in any information storage or retrieval system, without written permission from
the publishers.
For permission to photocopy or use material electronically from this work, please access
www. copyright.com (http://www.copyright.com/) or contact the Copyright Clearance
Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a
not-for-profit organization that provides licenses and registration for a variety of users. For
organizations that have been granted a photocopy license by the CCC, a separate system of
payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks,
and are used only for identification and explanation without intent to infringe.
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
Main entry under title:
Emission Control from Industrial Boilers
Bibliography: p.
Includes index p. 189
Library of Congress Catalog Card No. 94-61079
Table of Contents
Preface ix
Acknowledgements xi
1- THE CLEAN AIR ACT.........................................................................1
FRANK W. SHERMAN and HOWARD E. HESKETH
1.1 Background 1
1.2 Coexisting with the CAAA 2
1.3 The CAA Amendments of 1990 4
1.4 Title I: Non-Attainment Provisions 4
1.5 Title III: Hazardous Air Pollutants (HAPs) 9
1.6 Title IV: Acid Rain 11
1.7 Title V: Operating Permits 13
1.8 Title VI: Enforcement 15
2. PERMITTING PROCEDURES..........................................................17
LYNDA M. WIESE
2.1 Overview 17
2.2 Emission Limits 17
2.3 Construction Permits —New Source Review 18
2.4 Operation Permits 23
2.5 Compliance Demonstration 23
2.6 New Requirements 24
3. TYPES OF BOILER SYSTEMS AND
COMBUSTION FUNDAMENTALS....................................................25
FRANK L. CROSS, JR. and HOWARD E. HESKETH
3.1 Introduction 25
v
vi Table of Contents
3.2 Air Pollution Considerations 25
3.3 The Spreader Stoker 28
3.4 Waste Heat Boilers 29
3.5 Small Boilers 32
3.6 Comparative Data for System Air
Pollution Controls with and
without Waste Heat Boilers 32
3.7 Combustion Fundamentals for Fuels with Air 38
3.8 Convenient Correlation Data 40
4. COMPLIANCE TESTING.................................................................41
FRANK L. CROSS, JR.
4.1 The Source Test 41
4.2 Typical Stack Sampling Test Plan 43
4.3 Example Test Plan 47
4.4 Modified Method 5 Test Method
for Condensible Particulate 52
4.5 Example Outline of a Stack Test Report 53
4.6 Standard and Specialized Testing 55
4.7 Continuous Monitors 57
4.8 Combustion Gas Monitoring 60
5. SURVEY OF AIR POLLUTION CONTROL TECHNIQUES..........65
FRANK L. CROSS, JR.
5.1 Introduction 65
5.2 Data Required for Air Pollution Control Systems 65
5.3 Comparison of Control Devices 69
5.4 Specifications for Wet Scrubber Systems 69
5.5 Type of Control Systems 78
6. CYCLONIC DUST COLLECTORS....................................................79
DAVID L. AMREIN
6.1 Introduction 79
6.2 The Inlet 85
6.3 The Body Section 86
6.4 The Cone Section 86
6.5 The Receiver or Spinout 88
6.6 The Outlet Pipe/Vortex Finder 89
6.7 Cyclone Myths 89
6.8 Cost Considerations 90
6.9 Space Requirements 92
6.10 Cyclones Compared to Other Control Devices 93
Table of Contents vii
6.11 Cyclone Troubleshooting 93
6.12 Gas Conditions at Collector Inlet 94
7. PRINCIPLES OF WET SCRUBBERS................................. .97
HOWARD E. HESKETH
7.1 Introduction 97
7.2 Systems 97
7.3 Particle Size 98
7.4 Coal-Fired Boiler 98
7.5 Scrubber Characteristics 100
7.6 Atomization 101
7.7 Particle Control Mechanisms 103
7.8 Venturi Scrubbers 106
7.9 Countercurrent and Cross-Flow Scrubbers 107
7.10 Waste Energy Powered Scrubbers 107
7.11 Unique Scrubbers 108
7.12 General Information 110
7.13 Mist Elimination/Separation 110
7.14 Operating Characteristics 111
7.15 Wet Scrubbing Systems 114
8. PRINCIPLES OF DRY SCRUBBERS................................. .119
FRANK L. CROSS, JR.
8.1 Introduction 119
8.2 Chemistry for Acid Gas Control 119
8.3 Dry Scrubbers 120
8.4 Retrofit for Boiler Systems 122
8.5 Specifications 127
8.6 Cost Factors 140
9. PRINCIPLES OF OPERATION OF FABRIC FILTERS.... .141
RICHARD BUNDY
9.1 History 141
9.2 Theory of Operation 141
9.3 Components of a Baghouse 142
9.4 Types of Fabric Filters 143
9.5 Side Stream Systems 145
9.6 Critical Design Issues 145
9.7 Summary 152
10. THE COST OF CONTROL AND RETROFITS .153
HOWARD E. HESKETH
10.1 Introduction 153
viii Table of Contents
10.2 Generalized Equipment Costs 155
10.3 Cost Extrapolation 158
10.4 Estimating Capital Cost from Purchase Cost 160
10.5 Annual Operating Costs 161
10.6 References 162
11. DISPOSAL OF RESIDUALS FROM
INDUSTRIAL BOILERS...................................................................163
PATRICK WALSH
11.1 Types of Residuals 163
11.2 Legal Classification of Residuals 164
11.3 Handling and Transporting Ash 167
11.4 Ash Disposal 168
11.5 Ash as a Building Material 169
11.6 Wastewater Management 170
12. COMBUSTION AND ENVIRONMENTAL
EMISSION MONITORING................................................................171
HOWARD E. HESKETH
12.1 Introduction 171
12.2 Fail Safety 172
12.3 Predicting Flue Gas Quantity and Composition 174
12.4 Stack Sampling 177
12.5 Continuous Emission Monitoring 179
12.6 Some Possible System Components and Costs 180
About the Authors 185
Index 189
Preface
The Clean Air Act Amendments (CAAA) of 1990 significantly affect
commercial and industrial combustion devices such as boilers, in­
cinerators and other burners. Under the new emission regulations already
promulgated and those being developed, compliance will require im­
proved equipment, more detailed operator training, new permits, more
complex monitoring and reporting, as well as other requirements. All
emissions must be considered, e.g., particulates and gases (acid, organic,
hazardous, NOx, ozone).
Many industrial boiler plants have been retrofitted to change fuel and/or
combustion operating conditions as a means to meet new air pollution con­
trol requirements. New regulations will continue to be developed by the
CAAA of 1990 that will require changes to other boilers and combustion
systems. This book is intended to acquaint industry with the equipment
and operating options that are available to reduce emissions while control­
ling costs.
Specific topics are addressed, including regulatory requirements, boiler
and burner equipment retrofits, combustion modification, air emission
control and monitoring equipment selection, maintenance and cost. The
twelve chapters of this book are written by seven different authors. The
authors use fifty-two figures and forty-four tables to help explain the writ­
ten text and to make it more interesting and useful to you, the reader.
Howard E. Hesketh, PE
Frank L. Cross, Jr., PE
John T. Quigley, PE
ix