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2/9/17

PC 703

Air Pollution Control


&
Design of Equipments

Dr. Hari Prasad Dasari


Assistant Professor
Chemical Engineering Department
National Institute of Technology Karnataka

Class Meeting Time: energyhari@nitk.edu.in


Mon: 2-3 9177304950
Tue: 3-4
Thu: 10-11
Fri : 11-12

Course Information
Air Pollution Control & Design of Equipments (PC703)
Programme: M.Tech (IPC)
Category: Programme Core (PC)
Credits (L-T-P): 04 (3-1-0)

Content:
Introduction. Air pollution laws and standards. Meteorological aspects of air pollution
dispersion. Air pollution sampling and measurements. Air pollution control methods
and design of equipments. Particulate emission control. Control of gaseous emissions.
Air pollution control in specific industries. Acid rain, green house effects, important air
pollution episodes.

References:
Martin Crawford, Pollution Control Theory, McGraw Hill, NY. 1976. Joe Ledbetter, Air
Pollution Part A&B, Marcel Dekker, NY, 1972.
Department:
Chemical Engineering
Chemical Engineering Department Dr. Hari Prasad Dasari

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Course Plan

Please check the hard copy (No. of lectures & topics)

Evaluation Method:

End-Exam: 50 Marks
Mid-Exam: 25 Marks
Minor Test 1 : 10 Marks
Minor Test 2 : 10 Marks
Assignments: 05 Marks

Chemical Engineering Department Dr. Hari Prasad Dasari

Chemical Engineering Department Dr. Hari Prasad Dasari

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Why We Need to Study This Course…

Chemical Engineering Department Dr. Hari Prasad Dasari

Aggravated Air pollution – Industry I

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Aggravated Air Pollution – Industry II

Chemical Engineering Department Dr. Hari Prasad Dasari

Transportation related causes of air pollution

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SOx and NOx pollution

Chemical Engineering Department Dr. Hari Prasad Dasari

Smog  over  Los  Angeles

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Smog  over  the  Sea  of  Japan

Chemical Engineering Department Dr. Hari Prasad Dasari

Natural sources

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Silent  Polluters

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Climate  change

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For Better and Long Life…

Chemical Engineering Department Dr. Hari Prasad Dasari

Air Pollution types, effects and


its control…

• Atmosphere as a Resource
• Types and Sources of Air Pollution
– Major Classes of Air Pollutants
– Sources of Outdoor Air Pollutants
– Urban Air Pollution
• Effects of Air Pollution
• Controlling Air Pollution

Chemical Engineering Department Dr. Hari Prasad Dasari

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Atmosphere  as  a  Resource


• Atmospheric  Composition
– Nitrogen  78.08%
– Oxygen    20.95%
– Argon    0.93%
– Carbon   dioxide  0.04%

• Ecosystem services
Blocks UV radiation
Moderates the climate
Redistributes water in the
hydrologic cycle

Chemical Engineering Department Dr. Hari Prasad Dasari

Types  and  Sources  of  Air  Pollution


• Air Pollution
– Chemicals added to the atmosphere by natural
events or human activities in high enough
concentrations to be harmful
Two categories

Primary Air Pollutant


Harmful substance that is emitted directly into the
atmosphere

Secondary Air Pollutant


Harmful substance formed in the atmosphere when a
primary air pollutant reacts with substances normally
found in the atmosphere or with other air pollutants
Chemical Engineering Department Dr. Hari Prasad Dasari

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Major  Air  Pollutants

Chemical Engineering Department Dr. Hari Prasad Dasari

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Major  Classes  of  Air  Pollutants

• Particulate  Material
• Nitrogen  Oxides
• Sulfur  Oxides
• Carbon  Oxides
• Hydrocarbons
• Ozone

Chemical Engineering Department Dr. Hari Prasad Dasari

Particulate Material…

• Thousands of different solid or liquid particles


suspended in air
– Includes: soil particles, soot, lead, asbestos, sea salt,
and sulfuric acid droplets

Dangerous for 2 reasons


May contain materials with toxic or carcinogenic effects.
Extremely small particles can become lodged in lungs.

Chemical Engineering Department Dr. Hari Prasad Dasari

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Nitrogen and Sulfur Oxides…


• Nitrogen  Oxides
– Gases  produced  by  the  chemical  interactions  between  
atmospheric  nitrogen  and  oxygen  at  high  temperature
– Problems
• Greenhouse  gases  
• Cause  difficulty  breathing
• Sulfur  Oxides
– Gases  produced  by  the  chemical  interactions  between  
sulfur   and  oxygen  
– Causes   acid  precipitation

Chemical Engineering Department Dr. Hari Prasad Dasari

Carbon  Oxides  and  Hydrocarbons

• Carbon  Oxides
– Gases  carbon  monoxide   (CO)  and  carbon  dioxide  (CO2 )  
– Greenhouse   gases
• Hydrocarbons
– Diverse  group  of  organic  compounds   that  contain  only  
hydrogen  and  carbon  (ex:  CH4 -­‐ methane)
– Some  are  related  to  photochemical   smog  and  
greenhouse  gases

Chemical Engineering Department Dr. Hari Prasad Dasari

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Ozone
• Tropospheric  Ozone
– Man-­‐ made  pollutant  in  the  lower  atmosphere
– Secondary  air  pollutant
– Component   of  photochemical   smog
• Stratospheric  Ozone
– Essential  component   that  screens  out  UV  radiation  in  the  
upper  atmosphere
– Man-­‐ made  pollutants  (ex:  CFCs)   can  destroy  it

Chemical Engineering Department Dr. Hari Prasad Dasari

Sources  of  Outdoor  Air  Pollution

• Two  main  sources


– Transportation
– Industry
• Intentional  forest  
fires  is  also  high

Chemical Engineering Department Dr. Hari Prasad Dasari

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Urban  Air  Pollution


• Photochemical  Smog  (ex:  Los  A ngeles  below)
– Brownish-­‐orange  haze  formed  by  c hemical  reactions  i nvolving  
sunlight,  nitrogen  oxide,  and  hydrocarbons  

Chemical Engineering Department Dr. Hari Prasad Dasari

Formation  of  Photochemical  Smog

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Sources  of  Smog  in  Los  Angeles

Chemical Engineering Department Dr. Hari Prasad Dasari

Case-­‐In-­‐Point  Air  Pollution  in  Beijing  and  


Mexico  City

• Beijing  (left)
• Mexico  City  (above)
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Effects  of  Air  Pollution

• Low  level  exposure


– Irritates  eyes
– Causes   inflammation  of  respiratory  tract
• Can  develop  into  chronic  respiratory  diseases

Chemical Engineering Department Dr. Hari Prasad Dasari

Chemical Engineering Department Dr. Hari Prasad Dasari

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Health  Effects  of  Air  Pollution


• Sulfur  Dioxide  and  Particulate  material
– Irritate  respiratory  tract  and  impair  ability  of  lungs  
to  exchange  gases
• Nitrogen  Dioxides
– Causes   airway  restriction
• Carbon  monoxide
– Binds  with  iron  in  blood   hemoglobin
– Causes   headache,  fatigue,  drowsiness,   death
• Ozone
– Causes   burning  eyes,  coughing,   and  chest  
discomfort
Chemical Engineering Department Dr. Hari Prasad Dasari

Children  and  Air  Pollution

• Greater health threat to children than


adults
– Air pollution can restrict lung development
– Children breath more often than adults

• Children who live in high ozone areas are


more likely to develop asthma

Chemical Engineering Department Dr. Hari Prasad Dasari

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Controlling  Air  Pollution

• Smokestacks  with  electrostatic  


precipitator  (right)

Chemical Engineering Department Dr. Hari Prasad Dasari

Controlling  Air  Pollution

• Smokestacks with
scrubbers (right)

• Particulate material can


also be controlled by
proper excavating
techniques

Chemical Engineering Department Dr. Hari Prasad Dasari

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Controlling  Air  Pollution

• Phase  I  Vapor   Recovery  S ystem  for  gasoline

Chemical Engineering Department Dr. Hari Prasad Dasari

The  Clean  Air  Act

• Authorizes EPA to set limits


on amount of specific air
pollutants permitted
• Focuses on 6 pollutants:
– lead, particulate matter, sulfur
dioxide, carbon monoxide,
nitrogen oxides, and ozone

• Act has led to decreases!

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Chemical Engineering Department Dr. Hari Prasad Dasari

Other  Ways  to  Improve  Air  Quality

• Reduce sulfur content in gasoline from its


current average of 330 ppm to 30 ppm
– Sulfur clogs catalytic converters
• Require federal emission standards for all
passenger vehicles
– Including SUVs, trucks and minivans
• Require emission testing for all vehicles
– Including diesel

Chemical Engineering Department Dr. Hari Prasad Dasari

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Ozone  Depletion  in  Stratosphere


• Ozone  Protects  earth  from  UV  radiation
– Part  of  the  electromagnetic  spectrum  w ith  w avelengths  
just  shorter   than  visible  light  

Chemical Engineering Department Dr. Hari Prasad Dasari

Ozone  Depletion  in  Stratosphere

• Ozone thinning/hole
– First identified in 1985
over Antarctica
• Caused by
– human-produced
bromine and chlorine
containing chemicals
– Ex: CFCs

Chemical Engineering Department Dr. Hari Prasad Dasari

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Ozone  Depletion  in  Stratosphere

• Hole  over  Antarctica  requires  two  conditions:


– Sunlight  just  returning  to  polar  region
– Circumpolar  vortex-­‐ a  mass  of  cold  air  that  
circulates  around  the  southern   polar  region  
• Isolates  it  from  the  w armer  air  in  the  rest  of  the  planet  
• Polar  stratospheric  clouds  form
– Enables  Cl  and  Br  to  destroy  ozone

Chemical Engineering Department Dr. Hari Prasad Dasari

Effects  of  Ozone  Depletion


• Higher  levels  of  UV-­‐
radiation  hitting  the  
earth
– Eye  cataracts
– Skin   cancer  (right)
– Weakened  immunity
• May  disrupt  
ecosystems
• May  damage  crops  
and  forests
Chemical Engineering Department Dr. Hari Prasad Dasari

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Recovery  of  Ozone  Layer

• Montreal  Protocol  (1987)


– Reduction  of  CFCs
– Started  using  HCFCs  (greenhouse   gas)
• Phase  out  of  all  ozone  destroying  chemicals  is  
underway  globally
• Satellite  pictures  in  2000  indicated  that  ozone  
layer  was  recovering
• Full  recovery  will  not  occur  until  2050

Chemical Engineering Department Dr. Hari Prasad Dasari

Acid  Deposition
• Sulfur   dioxide  and  nitrogen  dioxide  emissions   react  
with  water  vapor  in  the  atmosphere  and  form  acids  
that  return  to  the  surface  as  either  dry  or  wet  
deposition  
• pH  scale

Chemical Engineering Department Dr. Hari Prasad Dasari

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How  Acid  Deposition  Develops

Chemical Engineering Department Dr. Hari Prasad Dasari

Effects  of  Acid  Deposition

• Declining Aquatic Animal


Populations
• Thin-shelled eggs prevent
bird reproduction
– Because calcium is
unavailable in acidic
soil
• Forest decline
– Ex: Black forest in Germany
(50% is destroyed)

Chemical Engineering Department Dr. Hari Prasad Dasari

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Acid  Deposition  and  Forest  Decline

Chemical Engineering Department Dr. Hari Prasad Dasari

Air Pollution Around the World

• Air  quality  is  deteriorating  r apidly  in  


developing  countries
• Shenyang,  China
– Residents  only  see  sunlight  a  few  weeks  
each  year
• Developing  countries  have  older  cars
– Still  use  l eaded  gasoline
• 5  worst  cities  in  world
– Beijing,  China;  Mexico  City,  Mexico;  
Shanghai,  China;  Tehran,  Iran;  and  
Calcutta,  India  

Chemical Engineering Department Dr. Hari Prasad Dasari

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Long  Distance  Transport  of  Air  Pollutants

Chemical Engineering Department Dr. Hari Prasad Dasari

Indoor  Air  Pollution

• Pollutants  can  be  5 -­‐100X  greater  than  outdoors


• Most  common:
– Radon,  c igarette  smoke,  c arbon  monoxide,  nitrogen  dioxide,  
formaldehyde  pesticides,  l ead,  c leaning  solvents,  ozone,  and  asbestos  

Chemical Engineering Department Dr. Hari Prasad Dasari

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Chemical Engineering Department Dr. Hari Prasad Dasari

Air pollution control:


Source control, Principles of controls

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Source  Control  Technology  

• Air quality management sets the tools to control air


pollutant emissions.

• Control measurements describes the equipment,


processes or actions used to reduce air pollution.

• The extent of pollution reduction varies among


technologies and measures.

• The selection of control technologies depends on


environmental, engineering, economic factors and
pollutant type.
Chemical Engineering Department Dr. Hari Prasad Dasari

Settling  Chambers  

• Settling chambers use the force of gravity to remove solid particles.


• The gas stream enters a chamb er wh er e th e velocity of th e gas is
reduced. Large particles drop out of the gas an d are r ecollected in
hoppers. Bec ause settling chamb ers ar e effective in r emoving only
larger particles, th ey ar e used in conjunction with a mor e efficient
control device.

Settling  chambers  

Chemical Engineering Department Dr. Hari Prasad Dasari

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Cyclones  Collectors
• The general principle of inertia separation is that the particulate-
gas is forced to change direction. As gas changes direction, the
inertia of the particles causes them to continue in the original
direction and be separated from the gas stream.

• The walls of the cyclone narrow toward the bottom of the unit,
allowing the particles to be collected in a hopper.

• The cleaner air leaves the cyclone through the top of the chamber,
flowing upward in a spiral vortex, formed within a downward
moving spiral.

• Cyclones are efficient in removing large particles but are not as


efficient with smaller particles. For this reason, they are used with
other particulate control devices.

Figure:   Cyclone  Collector  


Chemical Engineering Department Dr. Hari Prasad Dasari

Cyclone  Collector  

Chemical Engineering Department Dr. Hari Prasad Dasari

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Venturi Scrubbers

• Venturi scrubbers use a liquid stream to remove solid


particles.

• In the venturi scrubber, gas with particulate matter passes


through a short tube with flared ends and a constricted
middle.

• This constriction causes the gas stream to speed up when


the pressure is increased.

Chemical Engineering Department Dr. Hari Prasad Dasari

• The difference in velocity and pressure resulting from the


constriction causes the particles and water to mix and
combine.

• The reduced velocity at the expanded section of the throat


allows the droplets of water containing the particles to drop
out of the gas stream.

• Venturi scrubbers are effective in removing small particles,


with removal efficiencies of up to 99 percent.

• One drawback of this device, however, is the production of


wastewater.

Chemical Engineering Department Dr. Hari Prasad Dasari

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Venturi scrubber  components  


Chemical Engineering Department Dr. Hari Prasad Dasari

Fabric  Filters

• Fabric filters, or baghouses, remove dust from a gas stream by


passing the stream through a porous fabric. (99% efficiency)

Fabric  filter  (baghouse)  components  

Chemical Engineering Department Dr. Hari Prasad Dasari

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• The selection of the fiber material and fabric


construction is important to baghouse performance.

• The fiber material from which the fabric is made must


have adequate strength characteristics at the maximum
gas temperature expected and adequate chemical
compatibility with both the gas and the collected dust.

• One disadvantage of the fabric filter is that high-


temperature gases often have to be cooled before
contacting the filter medium.

Chemical Engineering Department Dr. Hari Prasad Dasari

Electrostatic  Precipitators  (ESPs)  

• An ESP is a particle control device that uses electrical


forces to move the particles out of the flowing gas stream
and onto collector plates.

• The ESP places electrical charges on the particles,


causing them to be attracted to oppositely charged metal
plates located in the precipitator.

Chemical Engineering Department Dr. Hari Prasad Dasari

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• The particles are removed from the plates by "rapping" and


collected in a hopper located below the unit.

• The removal efficiencies for ESPs are highly variable;


however, for very small particles alone, the removal efficiency
is about 99 %.

• Electrostatic precipitators are not only used in utility


applications but also other industries (for other exhaust gas
particles) such as cement (dust), pulp & paper (salt cake &
lime dust), petrochemicals (sulfuric acid mist), and steel (dust
& fumes).
Chemical Engineering Department Dr. Hari Prasad Dasari

National  Ambient  Air  Quality  Standards  (NAAQS)

Enforce  n eeded   emission   Compute  n eeded  


reductions emissions  reductions

NO

Measure  ambient   air  


Start Is  it  acceptable?
quality

YES
Flow diagram Predict  future  air  q uality,  
of accounting  for  growth
NAAQS process

NO YES
Compute  and  enforce  future  
Is  it  acceptable? Stop
needed   emission  controls

Chemical Engineering Department Dr. Hari Prasad Dasari

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Cost-­‐Benefit  Philosophy  

The optimum level is not static, but can change as the circumstances change.
(As technology improves, the cost of pollution reduction may decrease)

Chemical Engineering Department Dr. Hari Prasad Dasari

As the pollution reduction increases (money (social cost) required also increases).

It may not be very expensive to clean up the bulk of most pollutants.

(As the reduction in pollutants approaches 100%, marginal cost of each additional
unit of pollution reduction rises dramatically)

If public funds are used for pollution control, there is a limit on how much money can
be spent before the budgets of other public services are negatively imparted.

A balance must therefore be found b/w social benefits of pollution reduction vs cost.

A proper balance b/w benefits & costs represents optimum economic level of
production.

Chemical Engineering Department Dr. Hari Prasad Dasari

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National  Ambient  Air  Quality  Standards  (NAAQS)  


(2002)

Pollutant Type Standard Averaging Time

SO2 Primary 75 ppb 1-hour


SO2 Secondary 0.5 ppm 3-hour
PM10 Primary & Secondary 150 µg/m3 24-hour
PM2.5 Primary 12 µg/m3 annual
PM2.5 Primary & Secondary 35 µg/m3 24-hour
CO Primary 35 ppm 1-hour
O3 Primary & Secondary 0.12 ppm 1-hour

NOX Primary & Secondary 0.053 ppm annual

Pb Primary & Secondary 0.15 µg/m3 rolling 3 months

Chemical Engineering Department Dr. Hari Prasad Dasari

Conversion Tables

Conversions for the units of weight

From Gram Kilogram Grain Ounce Pound


Gram 1 0.001 15.43 0.0353 0.0022
Kilogram 1000 1 1.543 x  1 0 4 35.02 2.2050
Grain 0.0648 6.48  x  1 0 -­‐5 1 0.0023 1.43x  1 0 -­‐4
Ounce 28.35 0.0284 437.5 1 0.0625
Pound 453.6 0.4536 7000 16 1

Chemical Engineering Department Dr. Hari Prasad Dasari

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Conversions for the units of length

From Centimeter Meter Inches Feet Yards


Centimeter 1 0.01 0.3937 0.0328 0.0109
Meter 100 1 39.37 32.80 1.0936
Inches 2.540 0.0254 1 0.0833 0.0278
Feet 30.48 0.3048 12.0 1 0.3333
Yards 91.44 0.9144 36.0 3 1

Chemical Engineering Department Dr. Hari Prasad Dasari

Conversions for the units of volume

From cm3 Liter m3 Inch3 Feet3


cm3 1 0.001 1x10 -6 0.061 3.53 x 10 -5

Liter 1000 1 0.001 60.98 0.0353


m3 1x106 1 6.1x104 5.31
Inch3 16.39 0.0164 1.64 x 10 -5 1 5.79 x 10 -4

Feet 3 2.83x104 28.32 0.0283 1728 1

Chemical Engineering Department Dr. Hari Prasad Dasari

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Conversions for the units of energy

From BTU Joule  (J) Foot  Pound


BTU 1 1055 778
Joule (J) 0.0009478 1 0.7376
Foot  P ound 0.001285 1.3558 1

Conversions for the units of temperature

From Fahrenheit (F) Celsius (o C) Kelvin (K)


Fahrenheit (F) F (F-32) x (5/9) [(F-32) x (5/9)]+ 273.15
Celsius (oC) [(C x 9/5)]+ 32 C C + 273.15
Kelvin (K) [(K-273.15) x (9/5)] + 32 K-273.15 K

Chemical Engineering Department Dr. Hari Prasad Dasari

In a source test, the stack was divided into four sectors, each of which had
the same cross-sectional area. The following velocities and pollutant
concentrations were measured in these sectors:

Sector No. Velocity (V) Concentration (c)


(m/s) (µg/m3)
1 10 500
2 12 600
3 14 650
4 15 675

What is the average concentration (cavg) in the gas flowing in this stack?

Chemical Engineering Department Dr. Hari Prasad Dasari

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The average concentration is (cavg)


cavg = Total Mass / Total Volume

For equal areas

(cavg) = 616 µg/m3

Chemical Engineering Department Dr. Hari Prasad Dasari

We have tested a plant’s emissions of particulates and found the following


data:

Sample No. Stack Velocity Particulate concentration (c)


(V) (ft/s) (g/m3)
1 50 500
2 60 300
3 40 700

Each sample represents the average over a 20-min period.


What is the average particle concentration in this stack over the whole 60
min of this test?

Chemical Engineering Department Dr. Hari Prasad Dasari

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A PM10 sampler runs for 23.5 hours at an average flow rate 51 ft3/min. the
tare weight of the filter was 48.02g, and the gross weight of the filter, dried to
the same humidity as the fresh filter, was 48.07g. What is the average PM10
content of the air?

Chemical Engineering Department Dr. Hari Prasad Dasari

Design Aspects of Cyclones

Introduction
Cyclones  provide  a  relatively  low-­‐cost  method  of  removing  particulate   matter  from  
exhaust  gas  streams.  

Their  removal  efficiency  is  accordingly   much  better  than  that  of  settling  
chambers.  

However,  cyclones  are  not  as  efficient  as  electrostatic   precipitators,   baghouses,  and  
venturi scrubbers   but  are  often  installed  as  pre-­‐cleaners   before  these  more  effective  
devices.  

Chemical Engineering Department Dr. Hari Prasad Dasari

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Separation Principle

Particle   Collection   Process

Particles   enter  the  device  with   the  flowing  gas  


(see  F ig);  the  gas  stream  is  forced   to  turn,   but  
the  larger  particles   have  more  momentum  
and  cannot  turn   with  the  gas.  

These  larger  particles   impact  and  fall  down  the  cyclone  wall  and  are  collected   in  a  
hopper.  

The  gas  stream  actually  turns   a  number   of  times  in  a  helical  pattern,  
much  like  the  funnel  of  a  tornado.  

Chemical Engineering Department Dr. Hari Prasad Dasari

The  range  of  particle   sizes  collected   in  a  cyclone  is  dependent   upon  the  overall  
diameter  and  relative  dimensions  of  the  device.  

Stacking  cyclones  in  series  or  in  parallel   can  provide  further   alternatives  for  
improving  overall  collection   efficiency.  

There  are  three  types  of  cyclones.  


They  are  usually  characterized   by  where  the  gas  enters  and  exits  the  cyclone  body  
(tangentially,   axially,  or  peripherally).  

(1) Top  Inlet


(2) Axial  Inlet
(3) Bottom   Inlet

Chemical Engineering Department Dr. Hari Prasad Dasari

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Axial Inlet

Top Inlet

Bottom Inlet
Chemical Engineering Department Dr. Hari Prasad Dasari

Nomenclature for a tangential entry cyclone.

Chemical Engineering Department Dr. Hari Prasad Dasari

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Cyclones in series

Cyclones in Parallel

Chemical Engineering Department Dr. Hari Prasad Dasari

Cyclones in series

Larger  particles   can  be  collected   in  the  first   cyclone  and  a  smaller,   more  efficient  
cyclone  can  collect   smaller  particles.  

Such  an  arrangement  can  reduce   dust  loading  in  the  second  cyclone  and  avoid  
problems   of  abrasion  and  plugging.  

If  the  first  cyclone  should  plug,   there  still  will   be  some  collection   occurring   in  the  second  
cyclone.  

The additional pressure drop produced by the second cyclone adds to the
overall pressure drop of the system.

“The higher pressure drop can be a disadvantage in such a series system


design.”

Chemical Engineering Department Dr. Hari Prasad Dasari

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Cyclones in Parallel

Cyclones  in  parallel  use  a  common  inlet,   higher  volumes  of  gas  can  be  treated   at  
reasonable  pressure   drops.  

In configurations where a common hopper is used, each cyclone should


have the same pressure drop.

The  axial  entry  type  minimizes  the  eddy  formation  that  is  common  in  tangential  
entry  cyclones.  

Chemical Engineering Department Dr. Hari Prasad Dasari

DESIGN  AND  PERFORMANCE  EQUATIONS  

Objects  moving  in  circular   paths  tend  to  move  away  from  the  center  of  their  
motion.  

The  object   moves  outward   as  if  a  force  is  pushing  it  out  (Centrifugal   Force).  

The  whirling   motion   of  the  gas  in  a  cyclone  causes  particulate   matter  in  the  gas  to  
sense  this   force  and  move  out  to  the  walls.  

An  expression   for  this  force  is  as  follows:  

Chemical Engineering Department Dr. Hari Prasad Dasari

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These  types  of  considerations   (equation),   in  conjunction   with  considerations   of  


cyclone  geometry  and  vortex  formation,   have  led  to  the  development  of  numerous  
performance   equations.  

These  equations   attempt  to  characterize  the  behavior  of  cyclones.  


(Some  work  well,  and  some  do  not  (Ex:  High  Pressure,   High  Temperature)  

Three  important   parameters  can  be  used  to  characterize   cyclone  performance:  

Chemical Engineering Department Dr. Hari Prasad Dasari

Cut diameter (dpc)

The  cut   diameter  is  defined   as  the  size  (diameter)  of  particles   collected   with  
50%  efficiency.  

It  is  a  convenient  way  of  defining  efficiency  for  a  control   device  since  it  provides  
information   on  the  effectiveness  for  a  particle   size  range.  

A  frequently   used  expression   for  cut  diameter  is:  

Chemical Engineering Department Dr. Hari Prasad Dasari

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Typical  size  efficiency  curve

Chemical Engineering Department Dr. Hari Prasad Dasari

Collection Efficiency (E)

A  number   of  equations   have  been  developed  for  determining   the  fractional   cyclone  
efficiency  (Ei )  for  a  given  size  particle.  

Fractional   Efficiency  is  defined  as  the  fraction   of  particles   of  a  given  size  collected   in  
the  cyclone,  compared   to  those   of  that  size  going  into  the  cyclone.  

Two  methods  of  calculating   cyclone  efficiency  

(1) Leith and  Licht theory   for  calculating  fractional   efficiency


(2) Lapple theory  for  calculating   fractional   efficiency  

Chemical Engineering Department Dr. Hari Prasad Dasari

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(1) Leith and Licht theory for calculating fractional efficiency (1973):

In  this  expression,   c  is  a  factor   that  is  a  function   only  of  the  cyclone’s   dimensions  

The value of n is dependent on the cyclone


diameter and temperature of the gas stream.

Chemical Engineering Department Dr. Hari Prasad Dasari

(2) Lapple theory for calculating fractional efficiency (1951):

Cyclone  collection   efficiency  (vs)  particle   size  ratio  

Chemical Engineering Department Dr. Hari Prasad Dasari

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The  sum  of  these  products   in  the  rightmost   section  of  the  box  will  give  the  
overall  efficiency.  

Chemical Engineering Department Dr. Hari Prasad Dasari

Pressure drop

The  pressure   drop  across  a  cyclone  is  an  important   parameter  to  the  purchaser   of  such  
equipment.  

Increased  pressure  drop  means  greater  costs  for  power  to  move  an  exhaust  gas  
through   the  control   device.  

With  cyclones,  an  increase  in  pressure  drop  usually  means  that  there   will  be  an  
improvement  in  collection   efficiency  

For  these  reasons,   there  have  been  many  attempts  to  predict   pressure  drops  from  
design  variables.  

The  idea  is  that  having  such  an  equation,   one  could  work  back  and  optimize   the  
design  of  new  cyclones.  

Chemical Engineering Department Dr. Hari Prasad Dasari

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An  expression   occasionally  used  is:  

where q = volumetric flow rate.


kc = dimensionless factor (vanes)
= 0.5 (without vanes)
= 1 (vanes that do not expand the entering gas or touch the outlet wall
= 2 (vanes that expand and touch the wall)

This  equation,   when  compared  to  experimental   data,  was  found  to  have  a  poor  
correlation   coefficient.  
Chemical Engineering Department Dr. Hari Prasad Dasari

The most popular of the empirical pressure drop equations has the form:

where Kc = proportionality factor

Low-efficiency cyclones 2–4 in H2O (5–10cm H2O)


Medium-efficiency cyclones 4–6 in H2O (10–15cm H2O)
High-efficiency cyclones 8–10 in H2O (20–25cm H2O)

Chemical Engineering Department Dr. Hari Prasad Dasari

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Changes in the performance characteristics

Chemical Engineering Department Dr. Hari Prasad Dasari

Effect of operation variables on cyclone and


performance:

Chemical Engineering Department Dr. Hari Prasad Dasari

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The  cut   diameter  for  a  specific  type  of  dust  collected   in  a  cyclone  was  found  to  be  25  
𝜇m.  I f  the  inlet   velocity  were  doubled,   what  would   the  cut   diameter  be?  

17.70  𝜇𝑚

Chemical Engineering Department Dr. Hari Prasad Dasari

A cyclone currently operates with an efficiency of 84%. Assuming that the flow rate is
increased by 33%, estimate a revised efficiency.

86.10%

Chemical Engineering Department Dr. Hari Prasad Dasari

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A  large  conventional   cyclone  (no  vanes)  handles  13,000  acfm (60F,  1  atm)  of  a  
particulate-­‐laden   gas.  The  cyclone  dimensions   are  as  follows:  

Cyclone  diameter  =8  ft


Diameter  of  gas  outlet  =  4  ft
Inlet  width  =  2  ft
Inlet  height  = 4  ft
Length  of  cylinder   = 16  ft
Height  of  cone  = 16  ft

What  is  the  estimated  pressure  drop   across  the  cyclone?  

Chemical Engineering Department Dr. Hari Prasad Dasari

where Kc = proportionality factor

Kc=0.024

Inlet velocity (v i) = q/A = 13000/(2*4) = 1625 ft/min = 27 ft/s

Chemical Engineering Department Dr. Hari Prasad Dasari

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𝜌 = 0.076  𝑙𝑏/𝑓𝑡 3

∆𝑃 = 0.024    𝑥  0.076  𝑥  272  

=1.32  in  H 2O

Chemical Engineering Department Dr. Hari Prasad Dasari

An  engineer   was  requested  to  determine   the  cut  size  diameter  and  overall  
collection   efficiency  of  a  cyclone  given  the  particle   size  distribution   of  a  dust  from  
a  cement  kiln.  Particle   size  distribution   and  other   pertinent   data  are  provided   in  
Table

Chemical Engineering Department Dr. Hari Prasad Dasari

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Additional data:
Inlet gas velocity to cyclone = 50 ft/s
Effective number of turns within cyclone = 5
Cyclone diameter = 10 ft
Cyclone inlet width 1= 2.5 ft
Gas Viscosity = 1.34 E -5 lb /(ft.s)
Density of the particle = 181 lb/ft 3

Chemical Engineering Department Dr. Hari Prasad Dasari

  9.94  𝜇𝑚

Chemical Engineering Department Dr. Hari Prasad Dasari

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66%

Chemical Engineering Department Dr. Hari Prasad Dasari

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