Air Pollution Control Tech

EEZG614, Air Pollution Control Technologies
Lecture 3: Particulate Removal Equipment: Horizontal

Settling Chamber
Dr. Somak Chatterjee
BITS Pilani
Pilani Campus
Assistant Professor, Department of Chemical Engineering
Review
• Types of Air Pollutant Sampling and Measurement
• Ambient Air Sampling
• Stack Sampling
BITS Pilani, Deemed to be University under Section 3, UGC Act

Contents
✓ Control Methods
✓ Source Correction Method
✓ Particulate Emission Control
✓ Gravitational Settling Chamber

Sampling examples
Mass Spectrometer Flame ionization detector
Grab Sampling Bubbler and Impinger sampling

CONTROL METHODS
Effective means of dealing with the problem of air pollution is
to:
✓ Prevent formation of pollutants
✓ Minimize their emission at the source itself
In case of industrial pollutants this is achieved by investigating
various approaches at an early stage of process design and
development.
Finally, those methods are selected which do not contribute to air
pollution or have minimum air pollution potential.
✓ These are known as source correction methods
When these methods do not achieve the level of air pollution
control:
✓ Use of effluent gas cleaning technique is made 5
CONTROL METHODS
➢ Source Correction
✓Raw Material Changes
✓Process Changes
✓Equipment Modification or Replacement
➢ Effluent Treatment
✓Particulate control
✓Gases and odors control
6
CONTROL METHODS
Source Correction Methods

• Raw material changes: If a particular raw
material is responsible for causing air pollution,
use of purer grade of raw material is often
beneficial and may reduce the formation of
undesirable impurities and byproducts or may
even eliminate the troublesome effluent.
• Example: Use of low-sulphur fuel in place of
high-sulphur ones.
CONTROL METHODS
• Process Changes: Process changes involving new or modified
techniques offer important way of lowering atmospheric pollutant
emissions. Radical changes in chemical and petrochemical refining
industries have resulted in minimizing of the release of materials to the
atmosphere.
• Ex. Rotary kilns are a major source of dust generation in cement
plants. Some degree of dust control may be achieved in the kiln
operation by adjusting operating conditions.
• Reduction of gas velocities within the kiln, modification of the rate and
location of feed introduction and employment of a dense curtain of
light-weight chain at the discharge end of the kiln can lead to dust
control.
CONTROL METHODS
• Equipment Modification or Replacement: With suitable modification or
replacement of process equipment pollutant emissions can be
minimized.
• Ex. 1) The unburnt CO and hydrocarbons in the cylinders of an
automobile engine, which are otherwise emitted into the atmosphere
through the tail pipe, can be burnt by injecting air into the hot exhaust
manifold of the engine.
• In petroleum refineries, hydrocarbon vapors are released into the
atmosphere from storage tanks due to temperature changes, direct
evaporation, and displacement during filling.
• These losses can be minimized by designing the tanks with floating roof
covers or by pressuring tanks.
CONTROL METHODS
• In addition to the above-mentioned source correction
methods, air pollutant emissions from industrial
operations can be reduced by proper equipment
maintenance, housekeeping and cleanliness in the
facilities and premises.
• Plants often have excessive leakage around ducts,
piping valves and pumps. Many such leaks can be
prevented by checking the seals and gaskets routinely.
• Floors, decks, storage bins, loading areas, and material
conveyors must be kept clean to reduce dust pollution.
CONTROL METHODS
Cleaning of gaseous effluent
• Removal of gaseous pollutant emissions after their formation
• Applied to those cases where emissions can not be prevented and pollution
control equipment becomes necessary to remove them from main gas
stream
• Economical to install them at the source (usually pollutants are present in
high concentration near source and in small volume than at a point far away
from the source, where pollutants are diluted by other process gases or air)
• Size of equipment directly proportional to the treated volume and
equipment cost drastically reduces by reducing exhaust volume
• Emission control equipment may be classified into two types: particulate
control and gas+odor control types
CONTROL METHODS
Cleaning of gaseous effluent
• For gaseous pollutants two methods are available:
• First type of method include: Wet absorption and Dry
absorption
• Second class involves methods depending on chemical
alteration of the pollutant, usually through combustion or
catalytic incineration
• Basic mechanism in cleaning is diffusion
• This depends on the diffusion of gaseous stream to a
collecting surface
PARTICULATE EMISSION CONTROL
• Particle sizes range generally from 100

μm down to 0.1 μm and even less
• Factors to be considered
– Physical and Chemical characteristics
– Size and Concentration
– Volume to be handled
– Temperature and Humidity
– Toxicity and Inflammability
13
COLLECTION EFFICIENCY
Represents system performance
Gravimetric efficiency Weight , collected
T =
Total , entering
Fractional efficiency
fraction in range i collected
i = 100
mi
n
 m i i
Overall efficiency T = i =1
percent
M
mi= amount in range ‘i’ entering the collector

M= Total amount entering the collector 14
FRACTIONAL EFFICIENCY CURVE
100
0 50
Particle diameter, m
15
24 March 2023 BITS Pilani, Deemed to be University under Section 3, UGC Act
Problem 1
An air pollution control device removes a particulate that is being
emitted at a concentration of 125,000 μg/m3 at an air flow rate of
180 m3/sec. The device removes 0.48 metric tons per day. What
are the concentration of the emission and the efficiency of
collection?
16
Problem 2
The following table shows the size distribution of a dust

sample and the fractional efficiency of removal in a gas
cleaning equipment. Calculate overall collector efficiency.
20
PARTICULATE CONTROL EQUIPMENT
The basic mechanisms of removing particulate matter from
as streams may be classified as:
1. Gravitational settling
2. Centrifugal impaction
3. Inertial impaction
4. Direct interception
5. Diffusion
6. Electrostatic precipitation

Equipment presently available, which make use of one or
more of the above mechanisms, fall into the following
five broad categories:
1. Gravitational settling chambers
2. Cyclone separators
3. Fabric filters
4. Electrostatic precipitators
5. Wet collectors (Scrubbers)

• Gravitational settling
➢ Settling chambers
• Centrifugal impaction
➢ Cyclone separators
• Inertial impaction
• Direct interception
➢ Fabric filters
• Diffusion
➢ Scrubbers
• Electrostatic precipitation
➢ ESP
25
PARTICLE RANGE FOR DIFFERENT
TYPES OF EQUIPMENTS
26
GRAVITATIONAL SETTLING
CHAMBERS
• Gravitational settling chambers are generally used to remove
large, abrasive particles (usually > 50 m) from gas streams.
• They offer low pressure drop and require simple maintenance,
but their efficiencies are quite low for particles smaller than 50
m, Since most of the troublesome particles have much smaller
sizes than 50 m.
• These devices are normally used as precleaners prior to passing
the gas stream through high efficiency collection devices.
• In the settling chamber the gas stream, with its entrained
particles, is allowed to flow at a low velocity, allowing
sufficient time for the particles to settle down.

CHAMBERS
• The simplest form of horizontal type settling chamber is shown
in following figure:

CHAMBERS

CHAMBERS

CHAMBERS
• A more elaborate settling chamber is the Howard type
whose simplified diagram is shown in Fig in next slide
• By inserting several trays, the collection efficiency of
the device is improved
• It is because, the gas flow velocity in the chamber
remains substantially the same
• Yet each particle has a much shorter distance to fall
before reaching the bottom of the passage between
trays.

CHAMBERS

CHAMBERS: DESIGN CONCEPTS
• For a settling chamber having dimensions L x W x H, and n
number of trays including the bottom surface, the hydraulic
diameter for flow passage between the trays is given by
2WH
Dh =
W + H
• And the Reynolds number,
vDh 
Re =

• Where v, the velocity inside the chamber, is given by
Q
v=
nWH
• Where Q = volumetric flow rate of the gas stream. Substituting
for v and Dh we get
2Q
Re =
n (W + H )
• The spacing between the trays, H, is given by

H
H =
n
• Provided there is no dust layer initially present on the tray surface,
Substituting for H in Eq. For Re , we have 2Q
Re =
 (nW + H )
If a layer of dust Hd is initially present, then H = H − H d
n
2Q
With this modification, Re =
 (nW + H − nH d )
For laminar flow conditions (Re < 2300) within the trays,
particles of size dp of a particular material will settle a
distance y with a terminal velocity vt in time t. During this
time the particles are transported a distance L with the
velocity of the gas stream. Equating these two, we have:
y L
=
vt v
The value of y can be found from a knowledge of the
particle settling velocity.
If the particles are uniformly distributed over the incoming
stream, the efficiency of collection
 = y H or
Lvt nWLvt
= =
vH Q
when y  H All particles of that size (or large) will

be collected in the settling chamber.

The terminal settling velocity of the particles is found by
equating the drag force on the particle with the weight
minus the buoyancy of the particle:
𝐹𝑜𝑟𝑐𝑒 𝑜𝑓 𝐺𝑟𝑎𝑣𝑖𝑡𝑦 = 𝜌𝑝 𝑔𝑉𝑃
𝐵𝑜𝑢𝑦𝑎𝑛𝑐𝑦 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒 = 𝜌𝑔 𝑔𝑉𝑃
𝑣2
𝑓𝑑 = 𝐶𝐷 𝐴𝑝 𝜌𝑔
2
𝐴𝑝 = Area of the particle perpendicular to the direction of
movement
𝜋 2 1 2
𝜋 3
𝐹 = 𝐶𝐷 𝑑𝑝 𝜌𝑔 𝑣𝑡 = 𝑑𝑝 𝜌𝑝 − 𝜌𝑔 𝑔
4 2 6
Where
p = density of the particle,
g = density of gas, and
dp = particle diameter.
Rearranging, we get
𝟒𝒈𝒅𝒑 𝝆𝒑 −𝝆𝒈
𝒗𝒕 = (1)
𝟑𝑪𝑫𝝆𝒈

Where CD is the drag coefficient which is related to the particle
Reynolds number,
Re p = d p  g vt /  g .
The general drag coefficient curve for spherical particles may
be represented by three relationships. In the Stokes’ law
region,
24
CD =  for Re p  1 (2)
Re p
In the turbulent region (Rep > 1000), the drag coefficient CD
becomes almost constant with a value of 0.45.
CD = 0.45 for Rep > 1000
Between this region and the Stokes’ law region of laminar
flow around the particle, there is the transition region.
Several empirical equations have been suggested for this
region, such as that given by Schiller and Naumann;
CD =
24
Re p
(
1 + 0.15 Re0p.687 )
Substituting Eq. (2) into Eq. (1), we can calculate the
terminal settling velocity in the Stokes’ region.
gd p2 ( p −  g )
vt =
18 g
In the transition region, where CD is a function of Rep, Eq.
(5.12) is difficult to solve except by a trial-and-error method.
This problem has been over-come by rearranging Eq. (1) as:
4 gd ( p −  g ) g
e
CD Re = 2 p
3
p 2
g
Values of CDRep2, CD and Rep are available in the Chemical

Engineering Handbook from which vt can be calculated.

The minimum particle size that can be removed with 100%
efficiency can be found from the following Eq.
18 g Q
d p , min =
nWLg ( p −  g )
For Turbulent flow, the following theoretical equation can be
used for calculating the collection efficiency
 nWLvt 
 = 1 − exp − 
 Q 
CHAMBERS
Factors causing deviations in efficiency:
• Hindered settling at high particle concentrations

• Non-uniform gas velocity over the settling height
and width
• Particle re-entrainment
• Turbulence

CHAMBERS
Advantages Disadvantages
• Low capital cost • Large size
• Low energy cost • Low collection
• Low operating cost efficiency
• Low pressure drop • Trays in multi tray
chambers may warp

PROBLEM 3
46
PROBLEM 4
A multi-tray settling chamber having 8 trays, including
the bottom surface, handles 6 𝑚3 /s of air at 200C.
The trays are spaced 0.25 m apart and the chamber
is to be 1 m wide and 4 m long.
• What is the minimum particle size of density
2000 kg/ 𝒎𝟑 that can be collected with 100%
efficiency?
• What will be the efficiency of the settling
chamber if 50 m particles are to be removed?
• Laminar flow condition within the chamber and
presence of no dust initially on trays may be
assumed
49
PROBLEM 5
A multi-tray settling chamber handles 6 𝑚3 /s of air at
20 degree C. There are 8 trays including the bottom
surface spaced 0.25 m apart. The chamber is 4 m
long and 1 m wide. For particles of density 2000 kg/
𝑚3 and sizes 70 and 25 m, Calculate:
• The residence time
• The distance settled
• Efficiency of collection
52
PROBLEM 6
Calculate minimum size of the particle that will be
removed with 100% efficiency from a settling chamber
of size 8m×4m×1.5m designed for a flow rate of 6
m3/sec at 75 ºC.
58
PROBLEM 7
Find the length of the simple gravity collector
required to remove 90% of 50μm diameter particles of
density 2.0g/cc. The bulk gas velocity is 0.5m/s and
the chamber is 3m in height. Calculate the length if
two trays are used for same efficiency.
61
PROBLEM 7 Soln
62
PROBLEM 8
Design a gravity settler to remove all the iron
particulates from a dust-laden gas stream with the
data given as:
𝑑𝑝 = 35μ uniform
Q = 3.6 m3/s
𝜌𝑝 =7.62 g/cc
63
PROBLEM 8 Soln
64
Thank you
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EEZG614, Air Pollution Control Technologies

Lecture 3: Particulate Removal Equipment: Horizontal

• Ambient Air Sampling

BITS Pilani, Deemed to be University under Section 3, UGC Act

✓ Source Correction Method

✓ Particulate Emission Control

✓ Gravitational Settling Chamber

BITS Pilani, Deemed to be University under Section 3, UGC Act

Mass Spectrometer Flame ionization detector

Grab Sampling Bubbler and Impinger sampling

Source Correction Methods

• Particle sizes range generally from 100

mi= amount in range ‘i’ entering the collector

The following table shows the size distribution of a dust

BITS Pilani, Deemed to be University under Section 3, UGC Act

BITS Pilani, Deemed to be University under Section 3, UGC Act

BITS Pilani, Deemed to be University under Section 3, UGC Act

BITS Pilani, Deemed to be University under Section 3, UGC Act

BITS Pilani, Deemed to be University under Section 3, UGC Act

BITS Pilani, Deemed to be University under Section 3, UGC Act

BITS Pilani, Deemed to be University under Section 3, UGC Act

BITS Pilani, Deemed to be University under Section 3, UGC Act

• The spacing between the trays, H, is given by

when y  H All particles of that size (or large) will

BITS Pilani, Deemed to be University under Section 3, UGC Act

BITS Pilani, Deemed to be University under Section 3, UGC Act

Values of CDRep2, CD and Rep are available in the Chemical

BITS Pilani, Deemed to be University under Section 3, UGC Act

• Hindered settling at high particle concentrations

BITS Pilani, Deemed to be University under Section 3, UGC Act

BITS Pilani, Deemed to be University under Section 3, UGC Act

65 BITS Pilani, Deemed to be University under Section 3, UGC Act

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