Hurricane Cyclones To Reduce Emissions of Dryer Cyclones in Glowood Pellet Plant April 2016

Transcription

1 Hurricane Cyclones To Reduce Emissions of Dryer Cyclones in Glowood Pellet Plant April 2016

2 ACS - Provider of high performance gas/solid separation at a lower total cost of ownership EFFICIENCY Multicyclones ACS Cyclone Systems ESPs Wet Venturi Scubbers Bag filters TOTAL COST OF OWNERSHIP By its superior efficiency, ACS cyclones displace other more maintenance demanding technologies, such as Bag Filters, or much more expensive ones, such as ESPs 2 2

3 Filtration and Separation Technologies Address Two Main Market Needs EMISSIONS CONTROL Environmental Improvement POWDER RECOVERY Serious Economic Added Value Increasingly strict Particulate Matter (PM) emission limits are being enforced worldwide. Poor air quality is the number 1 environmental cause of premature death in the EU* Majority of combustion processes are associated with PM Emissions. Cleaning hot gases is mandatory for heat recovery and to improve plant efficiency. Many other processes in large industrial plants are sources of PM: (Steel, Cement, Paper, Glass etc.). 60% of the world chemical related industries handle products in the fine powder form. Significant shares also apply to the Pharmaceutical Food Ingredients, and Mineral industries, among others. Virtually all powder processing industries need gas-solid separation Many are actively seeking to optimize the yield of their processes and reduce powder losses. *Source: EU Clean Policy Act

4 ACS has grown to become a worldwide reference In cyclones in 5 years of existence Established in May 2008 by Pedro Araújo and Romualdo Salcedo, supported by the CoHitec program and promoted by COTEC Backed by Espírito Santo Ventures in 2009 Headquarters in Porto, Portugal, with 17 employees today Unique scientific knowledge in cyclone design optimization and particle agglomeration modeling (PACyc) in partnership with the Engineering Faculty of Porto (FEUP) where it runs a pilot system for R&D. Has become a worldwide reference in cyclones, with over 120 successful installations in 30 countries in 6 years Scalable, profitable business model based on Clearly differentiated market position Optimized cyclone design and accurate efficiency prediction capabilities Validated right first time installation Introducing standardized solutions to meet a wide range of client industry applications ACS Office in Porto ACS Pilot System 4

5 Examples of Cyclones Hydrocyclone, Merial, 2014 Hurricane Cyclone, Arla, 2013 Hurricane System, Arcelor Mittal,

6 Despite numerous advantages, cyclones have low efficiency Reverse Flow Cyclones Benefits: Robust Absence of maintenance No pressure problems No moving parts. Work on a dry basis No temperature restrictions No electrostatic components. No filters Typically, Cyclones Have To Be Complemented With Other Separators Due To Their Low Efficiency Wide Industrial Application Problem: Low efficiency for particles < 10 µm* *1µm = 1/1000mm 6

7 Alternative technologies for emission control have operational and cost drawbacks USUAL SOURCES OF PM EMISSIONS: COMBUSTION PROCESSES: Boilers, Furnaces, Incinerators, Gasifiers. DRYING PROCESSES: Rotary dryers, vertical dryers APPLICATION EXAMPLES PROBLEMS OF EXISTING SOLUTIONS : Biomass Boilers District water heating Heat production in industry Steam production in industry Biomass Dryers Pellet manufacturing Particle board manufacturing Need for an affordable, efficient and problem free technology! Bag Filters Critical operational problems & high maintenance costs at high temperature or moisture. Electrofilters (ESPs) High investment cost & restricted applicability Wet Venturi Scubbers High operational costs and production of secondary wet pollution with associated treatment cists.

8 ACS Core Technology: Highly Efficient Cyclones obtained by a scientifical approach Understanding How Cyclones Work Difficult to model cyclone separation dynamics ACS has developed its own unique model for cyclone efficiency prediction which takes into account agglomeration (clustering) in turbulent flow fields Optimizing Cyclone Efficiency ACS can rapidly generate millions of virtual prototypes and, through numerical optimization, select the best geometry to each given cyclone application The optimization approach has resulted in multiple cyclone patents Unique Cyclonic Recirculation Systems ACS has further increased cyclone efficiency with unique patented recirculation systems, using pure mechanical or electrostatic dynamics (ReCyclone ) ACS competitive advantage is sustained by a unique ability to accurately estimate, and consequently guarantee, a requested efficiency, resulting in better cyclones, tuned for their specific application 8

9 (I) Understanding how cyclones work Several constrains are imposed on design Wide range of operating conditions: - 85ºC < T < 120ºC (negative T for cryogenic micronizers) mg/nm 3 < C_in < kg/nm 3 25 Nm 3 /h < Q < 150,000 Nm 3 /h (?) Type of product: solid dispersions, inhalable, injectable, microcapsules, tablets waste recovery, wide range of densities (non-porous, porous) This makes it impossible to have a single cyclone geometry to effectively deal with all cases 9

10 (I) Understanding how cyclones work Very different particle size distributions occur in any process (Ex: Spray Drying) Very Fine Medium Fine Coarse 10

11 (I) Understanding how cyclones work Effect of residence time inside a cyclone REF: p =1450 kg.m -3 D max = 6 µm t max = 10 ms C in = 700 mg.m -3 11

12 (I) Understanding how cyclones work Effect of maximum collision (target ) diameter 12

13 (I) Understanding how cyclones work Effect of inlet concentration 700 mg/m3 70 mg/m3 7 mg/m3 ML (not sensitive to C_in) 13

14 (I) Understanding how cyclones work Developing the best theory for cyclone collection Predicting particle agglomeration in cyclones (PACyc) Trajectories Agglomerate Formation 14

15 (I) Understanding how cyclones work Developing the best theory for cyclone collection Predicting particle agglomeration in cyclones (PACyc) Fluid Velocity t=t+ t Particle Trajectory NO Collision? YES Agglomeration? NO U p1 + U p2 YES D new & U new 15

16 (I) Understanding how cyclones work Developing the best theory for cyclone collection Grade Efficiency Curves for two experiments (theoretical and experimental results) 16

17 (II) Optimizing cyclone efficiency Designing the best cyclone system for each application Empirical development Cleaned gas 2 level factorial experiment 4 level factorial experiment 128 prototypes prototypes Dusty gas 8 dimensions D e b a D s h H 4 axial 4 radial D b Numerical optimization Able to generate millions of prototypes Dust

18 (II) Optimizing cyclone efficiency Designing the best cyclone system for each application Setting up a mathematic problem Maximize efficiency, conditioned to: Equality constrains Relevant design équations (cyclone modeling) Particle size distribution and density Gas flow rate and dust load Gas temperature, density and viscosity Inequality constrains Maximum pressure loss Saltation velocity Geometric constraints Solution: Numerically optimized cyclones

19 Dust Control In Biomass Drying Plants Two main points of dust reduction needs 2) Reduction of ash & wood dust Emissions from the dryer mg/nm 3 1) Reduction of burner ash Carry over to the dryer 19

20 Case Study 1) Reduction of burner ash carry over to the dryer Client EDP Energias de Portugal, an integrated utility company, generates, distributes, and supplies electricity in Portugal Location Portugal Mangualde Technology Hurricane (10 batteries of 6 cyclones) Application Fly ash reduction at high temperature in wood waste boiler. Objective: using the biomass boiler off gases instead of natural gas for the process. Dimension 247,000 m 3 305ºC Guaranteed Emissions < 100 mg/nm 3 Alternative technology No known alternative 20

21 Case Study 1) Reduction of burner ash carry over to the dryer 21

22 Case Study 1) Reduction of burner ash carry over to the dryer 22

23 Case Study 2) Reduction of ash & wood dust emissions from the dryer Typical Values for Particulate Matter (PM) Emissions: mg/Nm mg/nm 3 Emission Control Device Current Objective for most plants: 50 mg/nm 3 Multicyclones: Efficiency < 50% -> TPM Emissions: mg/nm 3 Bag Filters and ESPs are not used due to tars, which stick to the collecting surfaces. Venturi Scrubbers are not used due to high energy consumption, erosion and corrosion. WESP: Only real available solution in the Market 23

24 Reduction of ash & wood dust emissions from the dryer Advantages And Inconveniences Of WESPs Advantages Very efficient for PM10 and PM2.5 Can handle sticky tars Inconveniences Very high investment cost Waste water treatment requirement Clean water consumption or treatment requirement Operational problems in the water treatment process (corrosion, plugging ) There is a need for alternative solutions! 24

25 Reduction of ash & wood dust emissions from the dryer PSD s at the Outlet of Wood Dryers 25

26 Reduction of ash & wood dust emissions from the dryer PSD s at the Outlet of Wood Dryer Cyclones 26

27 Reduction of ash & wood dust emissions from the dryer ACS Solution Numerically Optimized Cyclones to reduce fine particles escaping the dryer cyclones 27

28 Reduction of ash & wood dust emissions from the dryer Case Study Avoid a WESP in Glowood pellet plant Portugal Date of conclusion 01/10/2014 Client Glowood Produces and sells wood pellets ( ton/y) Location Portugal Application PM emission reduction after dryer cyclones of rotary dryer. Dimension 71,839 am 3 87ºC Load into Cyclone 700 mg/nm 3 Expected Emissions <60 mg/nm 3 Alternative technology Wet Electrostatic Precipitator (WESP), 3-4 times more expensive

29 Reduction of ash & wood dust emissions from the dryer Case Study Avoid a WESP in Glowood pellet plant Portugal

30 Reduction of ash & wood dust emissions from the dryer Case Study Avoid a WESP in Glowood pellet plant Portugal 30

31 Reduction of ash & wood dust emissions from the dryer Case Study Avoid a WESP in Glowood pellet plant Portugal 31

32 Reduction of ash & wood dust emissions from the dryer Case Study Avoid a WESP in Glowood pellet plant Portugal

33 Reduction of ash & wood dust emissions from the dryer Other ongoing projects for < 50mg/Nm3 - Latvia 33

34 Reduction of ash & wood dust emissions from the dryer Other ongoing projects for < 50mg/Nm3 - Latvia F= Am3/h Cin414mg/Nm3 T=78ºC Outlet ducting From Dryer Cyclone Inlet ducting To ID Fan 8687 To Stach B 918* A Cout = 33-41mg/Nm A B NOTE: Patented equipment. This drawing is property of Advanced Cyclone Systems, S.A. It cannot be copied, reproduced or lended, partially or totally, directly or indirectly. Unless explicitely stated and agreed by Acs. Designation Generral Arrangement 12 HR 1150 Client / Project Granulas Inspection doors * Dimension can be changed according to requirements Revision 4 / Date - Revision 3 / Date - Revision 2 / Date - Revision 1 / Date - P1628 Date Scale / Sheet Size A3 Fase Name Bruno Verif. Aprov. Budgeting N.º FP_P1628_GA_R0 34