Fact sheets on air emission abatement techniques - Infomil

152 Pages·2009·3.65 MB·English

Fact sheets on air emission
abatement techniques

File: B8176
Registratio n number: MD-MV20090007
Version: 3
VITO/InfoMil

February 2009
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Table of contents

1 Introduction ................................................................................................5
2 Research lay-out and results .......................................................................6
3 Use of the fact sheets..................................................................................8
3.1 Selection and application of air emission abatement techniques.....................8
3.2 Lay-out fact sheets..................................................................................11
3.3 Sub-division of techniques........................................................................12
4 Fact sheets ................................................................................................14
4.1 Gravitation.............................................................................................14
Settling chamber / Gravitational separator...........................................................................15
Cyclone / Dust cyclone / Wet cyclone / Multi-cyclone / Vortex separation.................................18
4.2 Scrubbing ..............................................................................................22
Scrubbing (general) / Wet dust remover / Wet dust scrubber..................................................23
Spraying tower / Rotational scrubber / Dynamic scrubber......................................................26
Venturi-scrubber / Venturi-scrubber / Whirl scrubber.............................................................29
4.3 Filtration................................................................................................32
Fabric filter (filtering dust separator) / Tube filter / Bag filter..................................................33
Ceramic filter (filtering dust-separator) / Ceramic filter / High temperature filter / Candle filter....37
Two-stage dust filter.........................................................................................................40
Absolute filter / HEPA-filter / surface filter / cartridge filter / micro filter...................................43
Demister / Aerosol filter / Deep bed filter.............................................................................46
Dry electrostatic precipitator / Electrostatic precipitator (ESP) / Dry E-Filter / Dry ESP
/Dry electrostatic precipitator / Electro filter........................................................................48
Wet electrostatic precipitator / Wet E-filter / Wet ESP / Wet Electrostatic precipitator
/Electro-filter..................................................................................................................51
4.4 Condensation..........................................................................................54
Condenser / Heat exchanger / Odour control condensation (OCC)...........................................55
Cryocondensation / Cooled condensation.............................................................................58
4.5 Adsorption..............................................................................................61
Adsorption (general).........................................................................................................62
Adsorption of active coal / Active coal filtering / Coal filter......................................................65
Zeolite filter (adsorption) / Zeolite filter / Hefite filter............................................................69
Polymer adsorption...........................................................................................................72
Dry lime injection / dry lime-sorption / Fixed bed lime-sorption / Cascade adsorption.................75
Semi-dry lime injection / Spray-dry adsorption / Semi-dry lime adsorption
/Semi-wet lime sorption...................................................................................................78
4.6 Absorption..............................................................................................81
Gas scrubber (general) / Scrubber / Absorber / Air scrubber...................................................82
Acid gas scrubber / Acid scrubber.......................................................................................85
Alkaline gas scrubber........................................................................................................88
Gas scrubber alkaline-oxidative..........................................................................................91
4.7 Biological cleaning...................................................................................94
Biofiltration / Bio-bed / Biological filter / Bio-bed filter / Compost filter.....................................95
Biotrickling / Lavafilter / BTF / Biodenox..............................................................................99
Biological scrubber (general) / Bioscrubber / Bioscrubber.....................................................102
Moving bed trickling filter / MBTF......................................................................................105
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4.8 Thermal oxidation.................................................................................108
Thermal incinerator / Incinerator / Thermal oxidation..........................................................109
Catalytic incinerator / Catalytic oxidation (catox) / Thermocat...............................................113
Flare............................................................................................................................117
4.9 Cold oxidation.......................................................................................121
Ionization / Active oxygen injection / Ozone injection / Plasma cleaning.................................122
Photo oxidation / UV-oxidation.........................................................................................125
4.10 Chemical reduction................................................................................127
Selective non-catalytic reduction / SNCR...........................................................................128
Selective catalytic reduction / SCR....................................................................................130
Non-selective catalytic reduction / NSCR............................................................................133
4.11 Other techniques...................................................................................135
Membrane filtration / Solvent recuperation / Air separation with membranes..........................136
Vapor recovery unit / VRU...............................................................................................139
5 Additional research on specific techniques..............................................140
5.1 Techniques...........................................................................................140
5.2 Field-testing of emissions.......................................................................143
6 Cost effectiveness....................................................................................144
7 Recommendations for future research.....................................................145
8 Index.......................................................................................................146
9 Annexes...................................................................................................147
Annex 1 Field emission data.................................................................................148
Annex 2 Illustrative calculations of cost effectiveness..............................................149
Annex 3 List of suppliers who provided information.................................................150
10 Colophon..............................................................................................151
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1 Introduction

The fact sheets with basic information on air emission abatement techniques are meant to
answer the most frequently asked questions on these techniques. They are an aid in
determining the Best Available Techniques (BAT) in specific situations. They also are the Dutch
and Flemish input in the revision of the BREF Wastewater and gas treatment for the chemical
industry.

The fact sheets give a brief description of the functioning, efficiency, financial aspects, etcetera
of the air emission abatement techniques that have proven to work in the field. Because of the
standardized lay-out the information is easy to find. Based on the fact sheets a first selection
of the possible techniques for a specific application can be made. The primary target audience
of the fact sheets are the competent authorities, advisors and companies that are not or
barely familiar with the techniques. For detailed technical information one can contact the
suppliers.

The precursor of this document, publication, L26 ‘Fact sheets waste gas treatment techniques’
(2000), was issued in 1999. On behalf of InfoMil, DHV has researched the topicality of the
fact sheets en renewed them where necessary. The revision of the BAT Reference document
(BREF) Waste gas and water treatment for the chemical industry was a reason to check the
fact sheets for topicality. The information in these renewed fact sheets was offered as
information for the revision of this BREF. The range of application of the fact sheets however,
is broader than just the chemical industry.

In the Flanders region of Belgium, VITO provides similar information fact sheetvia ‘LUSS’
(starting 2004). LUSS is a system that may help with first explorations and final decisions on
possible air pollution abatement techniques. This system is digitally available through
http://www.emis.vito.be/luss/.
The renewal of the fact sheets took place in close cooperation with research institute VITO
and with suppliers, companies and governments. The research consisted of:

a) Literature study (including LUSS and BREFs);
b) Survey among Dutch suppliers;
c) Interviews with suppliers, companies and the competent authoritiy.

This manual is restricted to air emission abatement techniques that are currently applied on an
industrial scale. Techniques that are only applied on a research or laboratory scale are not
described in these fact sheets. Distinction between the techniques is based on their working
principle, such as: gravitational separation, filtering and adsorption; the most important
implementations are described in the fact sheets. The before mentioned techniques represent
the majority of air emission abatement techniques in existence, although not every single
existing technique can be found in this manual.

Reading directions
In chapter 2 the research and the resulting conclusions are briefly explained. Chapter 3
explains the use of the fact sheets, including an overview of the described techniques and the
most critical parameters per technique. Chapter 4 contains the 36 fact sheets in total. Chapter
5 displays the results of further research on some techniques. These techniques are relatively
new or interesting for further research, for different reasons. For a number of techniques the
topicality of the previously determined emission ranges was also judged. In chapter 6 some
examples are given of cost effectiveness calculations. Chapter 7 gives an overview of the
missing information (blank spots).

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2 Research lay-out and results

The predetermined lay-out of the renewal of the fact sheets is displayed in general outlines in
figure 1. The research project was guided by a commission wherein the competent authority,
the suppliers, the industry, the Ministry of VROM and InfoMil were represented.

Figure 1. Research project renewal fact sheets

Existing sheets
BREF, EPA,
3.1. Desk study, Kick off
LUSS, literature,
first analysis meeting
cost assessment
1st updated sheets
3.3. questionnaire
suppliers
Input from
literature,
Meeting with
competent
3.4. Analysis 2 project
authorities,
committee
Emission reports,
permits
3.5. Interviews
selected suppliers
3.6. Report &
Final meeting
updated sheets
The research plan assumed that for the renewal of the data, information would be gathered
from literature and from the internet (point 3.1 from figure 1), as well as from the market
(point 3.2 in figure 1).

The key literature and internet sources used are: BREFs, LUSS and the US Environmental
Protection Agency (EPA).
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In gaining information from the market, the suppliers played an essential part. By means of
amonst others a surveythey were interviewed about recent market developments regarding
their products. Over 80 suppliers were summoned and asked to answer a number of
questions regarding costs, new techniques and changes in techniques in their range of
products. The Organization of Suppliers of Environmental Equipment (VLM, about 30
members) approached its its membersabout. In spite of this, the response of the suppliers
was low: about 15%.

An important consequence of this low response is that the indexation of the costs is
primarily based on data from literature and only very little upon data from suppliers.
Simply applying an index number on the old economical numbers turned out to be
impossible in a number of cases. In one case the costs had decreased (minimum caustic
scrubber), while in another case the costs have remained the same or have risen sharply
(active coal).

The suppliers that did respond reported that the development of air emission abatement
techniques is slow. The techniques evolve, but there are no reports of revolutionary
developments. However, new variants of existing techniques and optimizations are
reported. These developments can be described as the fine-tuning of existing techniques. A
different development is the application of existing techniques within different sectors.
Stricter environmental legislation (emission requirements) within a specific sector is often
the cause . Chapter 5 further investigates the developments as reported by the suppliers
and competent authorities.

The research lay-out also aimed at verifying the efficiency and emission values through use
of measurement reports. Measurement reports were collected from the competent
authorities, suppliers of installations and from open information sources (internet). In
practice it sometimes turned out to be difficult to get clear to what specific configurations of
techniques the measurements apply. For this reason fewer measurements were collected
than was planned. In Annex 1 the gathered emission values are further investigated.
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3 Use of the fact sheets

3.1 Selection and application of air emission abatement
techniques

The factsheets containing basic information on air emission abatement techniques serve as
an aid in selecting the Best Available Techniques (BAT) in specific situations. The described
techniques can be applied after checking the applicability of process integrated measures
for preventing or decreasing the environmental impact, for example by switching to
different raw materials or recycling of emission streams. If this is not feasable, air emission
abatement techniques are to be considered.

In order to make a first selection of air emission abatement techniques, an overview-table
(table 3.1) is included. With the aid of this table a first choice can be made based on the
component to be removed, the flow or other critical process variables.

For a first selection of techniques for removing (fine) dust, figure 2 can be used as well. For
example, in figure 2 one can find that a cyclone and gravitation-separator are effective at a
larger dust load (about 10 g/m³) and particle size (>Hm 10), while a wet scrubber is more
effective for a smaller dust load and particle size. Sometimes a combination of techniques
is necessary to attain a low emission value.

(Source: D.R. Woods, Process design and engineering practice, Prentice Hall PTR, New Jersey,
ISBN 0-13-805755-9)
After the first indicative selection of techniques (table 3.1), the corresponding fact sheets
may be used to compare the techniques’ most important features and to further consider
their application in the situation concerned. Further elaboration may be needed for the
preferred technique, requiring more information than that offered in the fact sheet. In that
case one may decide to search for further expertise or information. One example of this is
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the calculation of a techniques’ cost effectiveness. The fact sheets do not always provide
sufficient information for calculating the cost effectiveness in a specific situation according
to the NeR1-method 4.13 (see also chapter 6).

Table 3.1. The table below indicates which chemicals can be removed by use of a specific
air emission abatement technique. If a technique’s primary goal is not the removal of a
specific pollution, but this pollution is (partly) removed by the technique, this is indicated
by a ‘+’.

Working Name Removed components Parameters
principle technique
]
Drydust Wetdus VOC SO2 NOx NH3 Inorganicgasses Odour Efficiency[% Indicationofappliedflow3/h][m Criticalparameters
Gravitational Sinking 100 – Fluid percentage
(cid:1) (cid:1) 10 -90
separation chamber 100,000
Cyclone (cid:1) (cid:1) 5-99 1–100,000 Fluid percentage
Dust scrubber Dust 720 – Pollution
(cid:1) (cid:1) (cid:2) (cid:1) (cid:1) (cid:2) (cid:2) 99
scrubber 170,000
Spray tower 1,000 – Temperature,
(cid:1) (cid:1) (cid:2) (cid:2) (cid:2) 70 - 99
50,000 pollution
Venturi 720 –
(cid:1) (cid:1) (cid:2) (cid:1) (cid:2) (cid:2) 50 -99
scrubber 100,000
Filters Fabric 300 – Temperature,
filter (cid:1) 99.95 1,800,000 fluid percentage

Ceramic 80 – 300 – Stickiness
(cid:1)
filter 99.99 1,800,000
Two-stage <75,000 Ingoing gas flow
(cid:1)
dust filter and speed
Absolute 99.99- 100 - 360 Fluid percentage
(cid:1)
filter 99.999
Demister (cid:1) (cid:2) (cid:2) <99 <150,000 Temperature
Dry Energy
97 - 1,800 –
electrostatic (cid:1) (cid:1) consumption,
>99.9 2,000,000
precipitator maintenance
Wet 1,800 – Energy
electrostatic (cid:1) (cid:1) 97 - 99 9,000,000 consumption,
precipitator maintenance
Condensation Condenser 100 – Saturation of
(cid:2) (cid:1) (cid:2) (cid:1) 60 -90
100,000 ingoing gas
Cryoconden- <5,000 Fluid percentage
(cid:1) >99
sation of ingoing gas
Adsorption Adsorption 100 – Fluid percentage,
(cid:1) (cid:1) (cid:1) 80 – 95
(general) 100,000 VOC conc.
Adsorption 100 – Fluid percentage,
(cid:1) (cid:1) (cid:1) 80 – 98
(active coal) 1,000,000 VOC conc.
Adsorption <100,000 Fluid percentage,
zeolites (cid:1) (cid:1) (cid:1) (cid:1) 80 - 99 dust in ingoing
gas
Adsorption - Dust in ingoing
(cid:1) (cid:1) 95 – 98
polymeric gas
Dry lime 10,000 – Temperature,
(cid:1) (cid:1) 10 - 95
injection 300,000 pressure
Semi dry <1,000,000
85 –
lime (cid:1) (cid:1)
>90
injection
Absorption Gas 50 - Temperature
(cid:2) (cid:2) (cid:1) (cid:1) (cid:1) (cid:1) 30 – 99
scrubber 500,000
Acid gas 50 – Temperature
(cid:2) (cid:2) (cid:1) (cid:1) (cid:1) (cid:1) 80 - 99
scrubber 500,000

1NeRisshortfor‘Nederlandseemissierichtlijnlucht’(Netherlandsemissionguidelinesforair).
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Working Name Removed components Parameters
principle technique
]
Drydust Wetdus VOC SO2 NOx NH3 Inorganicgasses Odour Efficiency[% Indicationofappliedflow3/h][m Criticalparameters
Alkaline gas 50 – Temperature
(cid:2) (cid:2) (cid:1) (cid:1) (cid:1) (cid:1) 90 - 99
scrubber 500,000
Gas 50 – Temperature
scrubber 500,000
(cid:1) 80 – 90
alkaline
oxidative
Biological Bio filtration 100 - Temperature
(cid:1) (cid:1) 70 – 95
cleaning 100,000
Bio trickling 1,000 - Temperature
(cid:1) (cid:1) (cid:1) (cid:1) 70 – 99
500,000
Biological - Temperature
(cid:1) (cid:1) (cid:1) (cid:1) 70 – 95
scrubber
Moving bed 5,000 - Temperature
80 - >
trickling (cid:1) (cid:1) (cid:1) 40,000
98
filter
Thermal Thermal 90 – 86,000 Ingoing
98 –
oxidation incinerator (cid:2) (cid:1) (cid:1) concentration
99,9
VOC
Catalytic 90 – 90,000 ingoing
incinerator (cid:2) (cid:1) (cid:1) 80 – 99 concentration
VOC
Flare <1,800,000 Caloric value of
(cid:1) >99
ingoing gas
Cold Ionization 80 – 20 – Fluid percentage
(cid:2) (cid:2) (cid:1)
oxidation 99.9 200,000 of ingoing gas
Photo 2,000 – Temperature,
(cid:1) (cid:1) (cid:2) (cid:1) 80 -98
oxidation 60,000 fluid percentage
Chemical Selective <200,000 High T required
reduction non-catalytic (cid:1) (cid:1) 40 -70
reduction
Selective <1,000,000 High T required
catalytic (cid:1) (cid:1) 80 - 97
reduction
Non- <35,000
selective
(cid:2) (cid:1) (cid:1) 90 – 98
catalytic
reduction
Remaining Membrane <3,000
(cid:1) (cid:1) 99.9
techniques filtration

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