PARTICULATE EMISSION

CONTROL BY MECHANICAL
SEPARATION AND WET
GAS SCRUBBING

Department of Chemical Engineering

Dr. Haripada Bhunia
 Presentation Outline
 Particulate emission control
• By mechanical separation
 Gravitational settling
 Cyclone separators
 Fabric filters
 Electrostatic precipitator

• By wet gas scrubbing

 Plate scrubber
 Packed-bed scrubber
 Spray scrubber
 Venturi scrubber
 Cyclone scrubber
 Impingement-entrainment scrubber
 Fluidized-bed scrubber
Department of Chemical Engineering, TIET 2/5/23
 PARTICULATE EMISSION CONTROL

BY MECHANICAL SEPARATION
The basic mechanism of removing particulate matter from gas stream is classified
as: (1) gravitational settling (2) centrifugal impaction (3) inertial impaction (4) direct
interception (5) diffusion and (6) electrostatic precipitation.

Equipment presently available, which make use of one or more of the above
mechanisms, fall into the following four broad categories: (A) gravitational settling
chambers, (B) cyclone separators, (C) fabric filters, (D) electrostatic precipitator.

Department of Chemical Engineering, TIET 2/5/23

 Contd.

A. Gravitational Settling Chambers

Gravitational settling chambers are generally used to remove large, abrasive particles
(usually >50 µm) from gas stream. It provides enlarged areas to minimize horizontal
velocities and allow time for the vertical velocity to carry the particle to the floor. The
usual velocity through settling chambers is between 0.5 to 2.5 m/s.

Advantage: Low pressure loss, simplicity of design and maintenance.

Disadvantage: Requires larger space and efficiency is low. Only larger sized
particles are separated out.

Department of Chemical Engineering, TIET 2/5/23

 Gravitational Settling

Gravitation settling chamber

Department of Chemical Engineering, TIET 2/5/23

 Contd.

Design of a gravitational settling chamber

If we assume that Stokes law applies, we can derive a formula for
calculating the minimum diameter of a particle collected at 100%
theoretical efficiency in a chamber of length L.

vt vh Where vt= terminal settling velocity, m/s

=           1
H L

Where, g=gravitational constant, m/s2; ρp= density of particle,

vt =
 
g ρ p - ρa d p2
          2 kg/m3; ρa=density air, kg/m3; dp= diameter of particle, m; µa=
9 μa
viscosity of air, kg/m.s; H = height of settling chamber, m;
vh= horizontal flow-through velocity, m/s; and L= length of

settling chamber, m.
Department of Chemical Engineering, TIET 2/5/23
 Contd.

Solving for dp gives an equation that predicts the largest-size particle that can be

removed with 100% efficiency from a settling chamber of given dimension.

 
dp =  18 μ a H v h            3
 
g L ρ - ρ
p a  


All particles larger than dp will also be removed with 100% efficiency, while the
efficiency for smaller particles is the ratio of their settling velocities to the
settling velocity of the dp particle.

Department of Chemical Engineering, TIET 2/5/23

 Contd.
B. Cyclone Separators
• A cyclone separator consists of a cylindrical shell, conical base, dust hopper and an inlet
where the dust-laden gas enters tangentially. Under the influence of the centrifugal force
generated by the spinning gas, the solid particles are thrown to the wall of the cyclone
as the gas spirals upward at the inside of the cone.

• The particles slide down the walls of the cone and into the hopper. The operating
efficiency of a cyclone depends on the magnitude of the centrifugal force exerted on the
particles. The greater the centrifugal force, the greater the spreading efficiency. The
magnitude of the centrifugal force generated depends on particle mass, gas velocity
within the cyclone, and cyclone diameter.
Department of Chemical Engineering, TIET 2/5/23
 Contd.

Where, Fc=centrifugal force, N; Mp=particulate mass, kg; vi equals

particle velocity, m/s; and R equals radius of the cyclone, m. From
vi2
Fc = M p     4 this equation, it can be seen that the centrifugal force on the
R

particles, and thus the collection efficiency of the cyclone collector

can be increased by decreasing R. Large-diameter cyclone have
good collection efficiencies for particles 40 to 50 µm in diameter.

Advantage: Relatively inexpensive, simple to design and maintain; requires less

floor area; low to moderate pressure loss.

Disadvantage: Requires much head room; collection efficiency is low for smaller
particles, quite sensitive to variable dust loading and flow rates.
Department of Chemical Engineering, TIET 2/5/23
 BY MECHANICAL SEPARATION …contd.
C. Fabric Filters
• In a fabric filter system, the particulate-laden gas stream passes through a woven or felted
fabric that filters out the particulate matter and allows the gas to pass through. Small
particles are initially retained on the fabric by direct interception, inertial impaction, diffusion,
electrostatic attraction, and gravitational settling. After a dust mat has formed on the fabric,
more efficient collection of submicron particle is accomplished by sieving.
• Filter bags usually tubular or envelope-shaped, are capable of removing most particles as
small as 0.5µm and will remove substantial quantity of particles as small as 0.1 µm. Filter
bags ranging from 1.8 to 9 m long, can be utilized in a bag house filter arrangement.
• As particulates build up on the inside surface of the bags, the pressure drop increases. Before
the pressure drop becomes too severe, the bag must be relieved of some of the particulate
layer. Fabric filter can be cleaned intermittently, periodically, or continuously
Department of Chemical Engineering, TIET 2/5/23
 FABRIC FILTERS ..contd.
Fabric and Fibre Characteristics

• Fabric filter may be classified according to filtering media: woven fabric or felt cloth. Woven
fabrics have a definite long range repeating pattern and have considerable porosity in the
direction of gas flow. These open spaces must be bridged by impaction of interception to form
a true filtering surface. Felted cloth consists of randomly oriented fibres, compressed into a mat
and needled to some loosely woven backing material to improve mechanical strength.

• The choice of fabric fibre is based primarily on operating temperature and the corrosiveness or
abrasiveness of the particle. Cotton is the least expensive fibre, and is preferably used in low
temperature dust collection service. Silicon coated glass fibre cloth is commonly employed in
high temperature applications. The glass fibre must be lubricated to prevent abrasion. All fibre
may be applied to the manufacture of woven and felt type fabrics.
Department of Chemical Engineering, TIET 2/5/23
 FABRIC FILTERS ..contd.
Fabric Filter System

• Fabric filter systems typically consist of a tubular

bag or an envelope, suspended or mounted in such
manner that the collected particles fall into hopper
when dislodged from fabric. The structure in which
the bags are hanged is known as a bag-house.

Advantage: Fabric filters can give high efficiency, and

can even remove very small particles in dry state.
Disadvantage: High temperature gasses need to be
cooled. The flue gasses must be dry to avoid
condensation and clogging. The fabric is liable to
chemical attacks.
Typical bag-house
Department of Chemical Engineering, TIET 2/5/23
 BY MECHANIAL SEPARATION …contd.
D. Electrostatic Precipitator

• The electrostatic precipitator is one of the most widely used device for controlling particulate
emission at industrial installations ranging from power plants, cement and paper mills to oil
refineries.

• Electrostatic precipitator is a physical process by which particles suspended in gas stream are
charged electrically and, under the influence of the electrical field, separated from the gas
stream.

• The precipitator system consists of a positively charged collecting surface and a high-voltage
discharge electrode wire suspended from an insulator at the top and held in passion by
weight at the bottom. At a very high DC voltage, of the order of 50kV, a corona discharge
occurs close to the negative electrode, setting up an electric field between the emitted and
the grounded surface.

Department of Chemical Engineering, TIET 2/5/23

 BY MECHANIAL SEPARATION …contd.
D. Electrostatic Precipitator …contd.
• The particle laden gas enters near the bottom and flows upward. The gas close to the negative
electrode is, thus, ionized upon passing through the corona. As the negative ions and electrons
migrate toward the grounded surface, they in turn charge the passing particles.
• The electrostatic field then draws the particles to the collector surface where they are
deposited. Periodically, the collected particles must be removed from the collecting surface.
This is done by rapping or vibrating the collector to dislodge the particles.
Advantages:
 Maintenance is nominal, useless corrosive and adhesive materials are present in flue gases.
 They can be operated at high temperature up to 300-450 oC.
Disadvantages:
 Higher initial cost.
 Sensitive to variable dust loading and flow rates.
 They use high voltage, and hence may pose risk to personal safety of the staff.
 Collection efficiency reduces with time.

Department of Chemical Engineering, TIET 2/5/23

 PARTICULATE EMISSION CONTROL BY WET GAS SCRUBBING

• Wet scrubber removes particulate matter from gas streams by incorporating the particles into
liquid droplets directly on contact. The basic function of a wet scrubber is to provide contact
between the scrubbing liquid, usually water and, the particulate to be collected. This contact
can be achieved in a variety of ways as the particles are confronted with so-called impaction
target, which can be wetted surface as in packed scrubbers or individual droplets as in spray
scrubbers. The basic collection mechanism is the same as in filters: inertial impaction,
interception and diffusion.

• Generally, impaction and interception are the predominant mechanism for particles of diameter
above 3 µm, and for particles of diameter below 0.3 µm diffusion begins to prevail. There are
many scrubber designs presently available where the contact between the scrubbing liquid and
the particles is achieved in a variety of ways. The major types are: (A) plate scrubber, (B)
packed-bed scrubber, (C) spray scrubber, (D) venturi scrubber, (E) cyclone scrubber, (F)
impingement-entrainment scrubber, and (G) fluidized-bed scrubber.

Department of Chemical Engineering, TIET 2/5/23

 BY WET GAS SCRUBBING …contd.

A. Plate Scrubber
• It contains a vertical tower containing one or more horizontal plates (trays).
Gas enters the bottom of the tower and must pass through perforations in
each plate as it flows countercurrent to the descending water stream.

• Collection efficiency increases as the diameter of the perforations decreases. A

cut diameter, that collected with 50% efficiency, of about µm aerodynamic
diameter can be achieved with 3.2-mm-diameter holes in a sieve plate.

Department of Chemical Engineering, TIET 2/5/23

 BY WET GAS SCRUBBING …contd.

B. Packed-bed Scrubber

• Operates similarly to packed-bed gas

absorber. Collection efficiency increases
as packing size decreases. A cut
diameter of 1.5 µm aerodynamic
diameter can be attained in columns
packed with 2.5 cm elements.

Packed–bed scrubber
Department of Chemical Engineering, TIET 2/5/23
 BY WET GAS SCRUBBING …contd.

C. Spray Scrubber

• Particles are collected by liquid drops that have been atomized by spray
nozzles. Horizontal and vertical gas flows are used, as well as spray introduced
co-current, countercurrent, or cross-flow to the gas.
• Collection efficiency depends on droplet size, gas velocity, liquid/gas ratio, and
droplet trajectories. For droplets falling at their terminal velocity, the optimum
droplet diameter for fine-particle collection lies in the range of 100 to 500 µm.
• Gravitational settling scrubbers can achieve cut diameters of about 2.0 µm. The
liquid/gas ratio is in the range of 0.001 to 0.01 m3/m3 of gas treated.

Department of Chemical Engineering, TIET 2/5/23

 BY WET GAS SCRUBBING ..contd.

D. Venturi Scrubber
• A moving gas stream is used to atomize liquids into droplets. High gas
velocities (60 to 120 m/s) lead to high relative velocities between gas and
particles and promote collection.
E. Cyclone Scrubber
• Drops can be introduced into the gas stream of a cyclone to collect particles.
The spray can be directed outward from a central manifold or inward from the
collector wall.

Department of Chemical Engineering, TIET 2/5/23

 BY WET GAS SCRUBBING ..contd.

F. Impingement-Entrainment Scrubber
• The gas is forced to impinge on a liquid surface to reach a gas exit. Some of
the liquid atomizes into drops that are entrained by the gas. The gas exit is
designed so as to minimize the loss of entrained droplets.

G. Fluidized-bed Scrubber

• A zone of fluidized packing is provided where gas and liquid can mix intimately.
Gas passes upward through the packing, while liquid is sprayed up from the
bottom and/or flows down over the top of the fluidized layer of packing.

Department of Chemical Engineering, TIET 2/5/23

Thank You

Department of Chemical Engineering, TIET 2/5/23