In this presentation i have made the design and development of De-Dusting system for the reduction of dust and chemical emission from the atmosphere of the steel industry (Electrotherm India Ltd.) [Final Semester project Mechanical Engineering 8th sem]
1) The filter cake that forms on the surface of the filter bags is what does the filtering, not the bags themselves. The cake protects the bags from dust.
2) When designing a dedusting system, the key components to consider are the equipment to be dedusted, dedusting pipes/valves, filter, fan/motor, and insulation. Design guidelines include airflow volumes, pipe sizes, filtration velocities below 1.3 m/s, and dust concentrations of 20-50 g/cubic meter.
3) Important factors for selecting filter bags include the type of filter and cleaning mechanism, moisture/temperature, dust properties, and providing high permeability, strength, and stability. The bag material
The document discusses fabric filter technology as an alternative to electrostatic precipitators for reducing emissions from coal-fired power plants. It provides details on the operating principles of fabric filters, components of fabric filter plants, and opportunities for localizing fabric filter bag manufacturing and installation in South Africa. Eskom is planning to replace electrostatic precipitators with more efficient fabric filter plants and seeks industry input on strategies for local manufacturing of filter bags.
The document discusses bag filters, which are air pollution control devices that use fabric filter bags to remove particulate matter from gas streams. It provides information on the basic concepts and components of bag filters, including how dust particles are collected on the surface of the filter bags and then dislodged by pulses of compressed air or other cleaning methods. It also discusses factors to consider when selecting a bag filter system and types of bag filter cleaning methods.
- Raw Material Handling Plant
- Dust Generation & Necessity of Control
- Types of Dust Control System
- Dust Collection System
- Air Cleaning Devices
- Bag House Dust Collector
This document provides an overview of dust collection and maintenance from Kice Industries. It discusses what dust is, why it is a problem, and where it occurs in facilities. It then covers dry-type collectors like cyclones and baghouse filters, explaining factors that affect their efficiency. The document emphasizes proper installation and maintenance, describing different baghouse configurations and cleaning systems. Formulas are presented for measuring air velocity, volume, and calculating ratios like air to cloth for baghouse design. Overall it aims to educate on best practices for dust control system design and operation.
Bag filter optimization in Cement IndustryNITIN ASNANI
This document provides guidance on designing and optimizing bag filter systems used for dedusting applications. It discusses key components of a dedusting system and factors to consider in the design such as equipment to be dedusted, air flow calculations, auxiliary equipment selection, and physical site parameters. The document outlines design guidelines for aspects like venting air volume, velocity norms, and insulation requirements. It also provides information on bag filter material selection, air to cloth ratios, and troubleshooting common issues.
The document discusses particulate control and mercury removal technologies at a coal power plant. It considers three types of baghouse designs: shaker, reverse air, and pulse jet. Pulse jet is preferred due to increased filter bag life, lower maintenance costs, and ability to continuously clean bags. Mercury removal relies on installing SCR to oxidize mercury so it can be captured by the baghouse and wet scrubber. Adding powdered activated carbon is not needed if SCR oxidation and wet scrubber removal achieve over 90% mercury reduction. Annual operating costs for the pulse jet baghouse design are estimated to be $6.6 million per year.
Thermax Limited provides consulting services for efficient steam systems, including piping design, equipment selection, and design of condensate recovery and waste heat recovery systems. They offer utilities audits to analyze steam, compressed air, cooling, and power systems with the goal of optimizing costs. Their expertise includes selection and sizing of equipment such as pressure reducing stations, traps, and insulation. High-pressure condensate recovery systems can provide fuel savings of 15-20% by recovering heat from flash steam and condensate.
1) The filter cake that forms on the surface of the filter bags is what does the filtering, not the bags themselves. The cake protects the bags from dust.
2) When designing a dedusting system, the key components to consider are the equipment to be dedusted, dedusting pipes/valves, filter, fan/motor, and insulation. Design guidelines include airflow volumes, pipe sizes, filtration velocities below 1.3 m/s, and dust concentrations of 20-50 g/cubic meter.
3) Important factors for selecting filter bags include the type of filter and cleaning mechanism, moisture/temperature, dust properties, and providing high permeability, strength, and stability. The bag material
The document discusses fabric filter technology as an alternative to electrostatic precipitators for reducing emissions from coal-fired power plants. It provides details on the operating principles of fabric filters, components of fabric filter plants, and opportunities for localizing fabric filter bag manufacturing and installation in South Africa. Eskom is planning to replace electrostatic precipitators with more efficient fabric filter plants and seeks industry input on strategies for local manufacturing of filter bags.
The document discusses bag filters, which are air pollution control devices that use fabric filter bags to remove particulate matter from gas streams. It provides information on the basic concepts and components of bag filters, including how dust particles are collected on the surface of the filter bags and then dislodged by pulses of compressed air or other cleaning methods. It also discusses factors to consider when selecting a bag filter system and types of bag filter cleaning methods.
- Raw Material Handling Plant
- Dust Generation & Necessity of Control
- Types of Dust Control System
- Dust Collection System
- Air Cleaning Devices
- Bag House Dust Collector
This document provides an overview of dust collection and maintenance from Kice Industries. It discusses what dust is, why it is a problem, and where it occurs in facilities. It then covers dry-type collectors like cyclones and baghouse filters, explaining factors that affect their efficiency. The document emphasizes proper installation and maintenance, describing different baghouse configurations and cleaning systems. Formulas are presented for measuring air velocity, volume, and calculating ratios like air to cloth for baghouse design. Overall it aims to educate on best practices for dust control system design and operation.
Bag filter optimization in Cement IndustryNITIN ASNANI
This document provides guidance on designing and optimizing bag filter systems used for dedusting applications. It discusses key components of a dedusting system and factors to consider in the design such as equipment to be dedusted, air flow calculations, auxiliary equipment selection, and physical site parameters. The document outlines design guidelines for aspects like venting air volume, velocity norms, and insulation requirements. It also provides information on bag filter material selection, air to cloth ratios, and troubleshooting common issues.
The document discusses particulate control and mercury removal technologies at a coal power plant. It considers three types of baghouse designs: shaker, reverse air, and pulse jet. Pulse jet is preferred due to increased filter bag life, lower maintenance costs, and ability to continuously clean bags. Mercury removal relies on installing SCR to oxidize mercury so it can be captured by the baghouse and wet scrubber. Adding powdered activated carbon is not needed if SCR oxidation and wet scrubber removal achieve over 90% mercury reduction. Annual operating costs for the pulse jet baghouse design are estimated to be $6.6 million per year.
Thermax Limited provides consulting services for efficient steam systems, including piping design, equipment selection, and design of condensate recovery and waste heat recovery systems. They offer utilities audits to analyze steam, compressed air, cooling, and power systems with the goal of optimizing costs. Their expertise includes selection and sizing of equipment such as pressure reducing stations, traps, and insulation. High-pressure condensate recovery systems can provide fuel savings of 15-20% by recovering heat from flash steam and condensate.
This document describes the design of a plant for cryogenic distillation of air into oxygen and nitrogen. It includes an introduction to air separation and the cryogenic process. Process equipment like compressors, heat exchangers, and distillation columns are designed. Mass and energy balances are performed. The distillation columns and condenser are designed and specifications are provided. An economic analysis includes capital costs, production costs, profitability metrics, payback period and safety considerations. References for design methods are also listed.
This document provides an overview of various types of dust collection equipment, beginning with cyclones and inertial separators. It describes how cyclones use centrifugal force to move dust particles toward the walls, while inertial separators rely on inertia and gravity to separate particles from the air stream. It highlights key design considerations for cyclones, such as diameter and barrel length, and discusses other inertial separator designs like multiple cyclones, rotary dry centrifugals, and louvers. The document aims to help readers understand the basic functioning of different pollution control equipment.
Ball mills are tube mills used for grinding materials like cement and involve several components. The document discusses the movement of grinding media in ball mills, optimal ball charge and filling levels, key components like linings, diaphragms, drives and bearings, and factors that influence mill operation such as ventilation, water injection and grinding aids. Case studies are presented to illustrate problems that can occur with improper ball charge sizes and material filling levels.
This document provides information on dedusting filters and their operation. It discusses the key components of a dedusting system including equipment to be dedusted, pipes, filters, fans, and insulation. It explains that the filter cake, not the bag itself, does most of the filtering. Guidelines are provided for filtration velocity, dust concentration, insulation needs, and other design factors. Filter bag selection criteria include the cleaning mechanism, dust properties, temperature, and allowed dust levels in cleaned gas.
It is the device that utilize specific configuration of N number of cyclones (diameter equal or greater than 300 mm) to treat higher volume of gas efficiently.
This document provides information about rotary kilns and their components. It discusses the kiln shell, tires, roller stations, drives, seals, and maintenance procedures. The main components covered are the splined and floating tires, inlet and outlet seals, supporting roller stations, and drive systems. Proper maintenance of the seals, tires, rollers and drives is emphasized.
Dust collectors and cross contaminationNimra Iqbal
Dust collectors are systems used to filter dust and impurities from industrial air streams. They typically include a blower, filter, cleaning system, and dust collection container. Common types include cyclones, wet scrubbers, and filters. Cyclones use centrifugal force to separate dust while wet scrubbers introduce gas streams into liquid to capture particles. Proper dust collector selection and specifications like air volume and velocity depend on the specific application to effectively control dust. HEPA and bag filters are commonly used and should meet standards to filter particles down to 0.3 microns.
Electrostatic precipitators use electrostatic charges to remove particulate matter from gas streams. They apply a strong electric field between discharge electrodes and collection plates or tubes. This charges particles as they pass through, forcing them to collect on the plates or tubes. Periodically, the collected particles are removed from the plates by rapping or water spraying and collected in a hopper. Key components include discharge electrodes, collection surfaces, a high voltage power supply, and a particle removal system.
A cyclone separator uses centrifugal force to separate particles from gas streams. It has a tangential inlet that spins the gas into a vortex. Larger, heavier particles are thrown outward against the wall and collected while smaller particles pass through. Key parameters that affect its performance include gas velocity, particle properties, and diameter-to-length ratio. It has advantages such as being dry, low cost, and requiring little maintenance. However, it is less efficient for small particles and has higher pressure drops than some other separators. Cyclone separators are commonly used in industries like mining, manufacturing, and energy production. Regular inspection and maintenance helps optimize its operation.
This document provides an introduction to flame arrestor technology, including the history and operating principles of flame arrestors. It discusses how Sir Humphry Davy discovered the principle of blocking flame propagation through narrow passages in 1815. Modern flame arrestors operate on the same principle, removing heat from the flame as it attempts to pass through narrow passages. The document outlines the different types of flame arrestors, how flames propagate when unconfined versus confined, and the development stages a confined flame can reach.
This document discusses performing a heat and mass balance (HMB) study on a cement plant. The objectives are to assess energy consumption, improve thermal efficiency, and identify areas of thermal losses. The study involves defining system boundaries, inputs, outputs, and performing mass balances. A case study on an ABC plant is presented where the overall mass balance was calculated based on measured input and output streams like kiln feed, fuel consumption, cooler vent air, and clinker production. The results can be used to optimize the pyroprocess and thermal energy usage.
Pneumatic conveying system of fly ash in a thermal power plantSoumyodeep Mukherjee
Fly ash is a byproduct of coal combustion that is captured by pollution control devices before being released into the atmosphere. There are two main types of fly ash removal systems - hydro sluicing and pneumatic conveying. Hydro sluicing uses large amounts of water and storage area and results in ash that cannot be used. Pneumatic conveying transports fly ash in a vacuum or with compressed air through pipes. The design of a pneumatic conveying system depends on accurate input parameters, component performance data, and theoretical calculations to reliably and efficiently transport fly ash from collection points to storage silos.
This document discusses fan concept and analysis in the cement industry. It provides information on static pressure, system resistance, gas properties, density correction factors, barometric pressure, and pitot tube measurements. It also discusses fan classifications, differences between fans and blowers/compressors, major process fans, system curves, fan laws, factors affecting fan performance, and calculations for fan efficiency, head, power savings, and damper losses. Case studies are presented on ESP exhaust fan retrofitting opportunities to increase efficiency.
The main objective of this presentation is that how to optimize the mill in pet coke grinding and what modification is required when changing from normal coal to pet coke.
ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILNISA Interchange
This paper highlights the efforts taken by the author in developing an Energy Model for the pyro-processing of Clinker production in a dry-process rotary cement kiln. In this paper this Energy Model is applied to a state of the art cement plant in a Far East Asian country. However this Energy Model is also applicable to all the modern dry process cement kilns. This model is based on actual field input data and site observations.
This document discusses ash handling systems for coal-fired power plants. It describes the types of ash generated - bottom ash and fly ash - and the difficulties in handling ash, which can be hot, cause dust and air pollution, and corrode equipment. The key requirements for effective ash handling systems are conveyed. Various ash handling system types are then outlined, including manual wheelbarrows, mechanical systems like bucket elevators and conveyors, and pneumatic conveyor systems. Final ash disposal and reuse options are also summarized.
Download Link (Copy URL):
https://sites.google.com/view/varunpratapsingh/teaching-engagements
This PPT contained slides for Steam distribution system, which is a third unit in Energy Conservation subject of final year in Mechanical Engineering Branch.
The content of PPT are mentioned below:
Steam Distribution System, Thermodynamics, Heat, Properties of steam, steam, steam system, PDRS, Steam pipe installation, Dryers, Operation and maintenance of steam traps, Condensate Recovery System, Flash Recovery System, Energy Conservation Opportunity in Steam Distribution System.
Cements Ground in the Vertical Roller Mill Fulfil the Quality Requirements of...LOESCHE
The document discusses concerns that cements ground in vertical roller mills may not meet quality requirements for the market. It summarizes that testing over the past 15 years has shown these concerns to be unfounded, as the quality of cement from vertical roller mills is as good as or sometimes better than cement from ball mills. The key areas of previous concern - water demand, strength development, and setting times - have all been shown to meet market standards for cement ground in vertical roller mills.
This document summarizes the key aspects of a dust suppression system. It discusses the types of dust generated in industrial processes and why dust control is necessary to protect health, safety and equipment. It then outlines the main approaches to dust control, including dust collection systems, wet suppression using water sprays, and airborne dust capture. Specific considerations for configuring an effective wet suppression system are covered, such as nozzle selection, droplet size and spray pattern.
NOx SOx CO2 and Urea Dust Control inFertilizers Plants.pdfPremBaboo4
NOx, SOx & CO2 emission are the serious problem in any fertilizers plant. The urea production and use of nitrogen fertilizers lead to the release of SOx, CO2, N2O and CH4, which are among the most important global GHGs. The synthesis of ammonia, from which all synthetic fertilizers are produced, accounts alone for about 0.8% of the global GHG emissions and 2% of global energy. CO2 emission factor from urea is 0.2 kg Carbon per kg urea, which is equivalent to the mass percent of Carbon in urea. Urea dust control system should be there in every plant. The pollution point of view urea dust is very harmful to buildings and humans. If you install CO2 recovery system, then you can also control SOx and NOx. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.
The document discusses the basics of dedusting filters used in cement plants. It covers key principles such as the formation of dust cake on filter bags, design guidelines for filtration velocity and air-to-cloth ratios, selection criteria for filter bags, and components of a dust collection system including equipment to be dedusted, dedusting pipes, filters, fans and insulation. Guidelines are provided for hooding, air velocities, dust concentrations and other parameters to ensure trouble-free operation of dedusting plants.
This document describes the design of a plant for cryogenic distillation of air into oxygen and nitrogen. It includes an introduction to air separation and the cryogenic process. Process equipment like compressors, heat exchangers, and distillation columns are designed. Mass and energy balances are performed. The distillation columns and condenser are designed and specifications are provided. An economic analysis includes capital costs, production costs, profitability metrics, payback period and safety considerations. References for design methods are also listed.
This document provides an overview of various types of dust collection equipment, beginning with cyclones and inertial separators. It describes how cyclones use centrifugal force to move dust particles toward the walls, while inertial separators rely on inertia and gravity to separate particles from the air stream. It highlights key design considerations for cyclones, such as diameter and barrel length, and discusses other inertial separator designs like multiple cyclones, rotary dry centrifugals, and louvers. The document aims to help readers understand the basic functioning of different pollution control equipment.
Ball mills are tube mills used for grinding materials like cement and involve several components. The document discusses the movement of grinding media in ball mills, optimal ball charge and filling levels, key components like linings, diaphragms, drives and bearings, and factors that influence mill operation such as ventilation, water injection and grinding aids. Case studies are presented to illustrate problems that can occur with improper ball charge sizes and material filling levels.
This document provides information on dedusting filters and their operation. It discusses the key components of a dedusting system including equipment to be dedusted, pipes, filters, fans, and insulation. It explains that the filter cake, not the bag itself, does most of the filtering. Guidelines are provided for filtration velocity, dust concentration, insulation needs, and other design factors. Filter bag selection criteria include the cleaning mechanism, dust properties, temperature, and allowed dust levels in cleaned gas.
It is the device that utilize specific configuration of N number of cyclones (diameter equal or greater than 300 mm) to treat higher volume of gas efficiently.
This document provides information about rotary kilns and their components. It discusses the kiln shell, tires, roller stations, drives, seals, and maintenance procedures. The main components covered are the splined and floating tires, inlet and outlet seals, supporting roller stations, and drive systems. Proper maintenance of the seals, tires, rollers and drives is emphasized.
Dust collectors and cross contaminationNimra Iqbal
Dust collectors are systems used to filter dust and impurities from industrial air streams. They typically include a blower, filter, cleaning system, and dust collection container. Common types include cyclones, wet scrubbers, and filters. Cyclones use centrifugal force to separate dust while wet scrubbers introduce gas streams into liquid to capture particles. Proper dust collector selection and specifications like air volume and velocity depend on the specific application to effectively control dust. HEPA and bag filters are commonly used and should meet standards to filter particles down to 0.3 microns.
Electrostatic precipitators use electrostatic charges to remove particulate matter from gas streams. They apply a strong electric field between discharge electrodes and collection plates or tubes. This charges particles as they pass through, forcing them to collect on the plates or tubes. Periodically, the collected particles are removed from the plates by rapping or water spraying and collected in a hopper. Key components include discharge electrodes, collection surfaces, a high voltage power supply, and a particle removal system.
A cyclone separator uses centrifugal force to separate particles from gas streams. It has a tangential inlet that spins the gas into a vortex. Larger, heavier particles are thrown outward against the wall and collected while smaller particles pass through. Key parameters that affect its performance include gas velocity, particle properties, and diameter-to-length ratio. It has advantages such as being dry, low cost, and requiring little maintenance. However, it is less efficient for small particles and has higher pressure drops than some other separators. Cyclone separators are commonly used in industries like mining, manufacturing, and energy production. Regular inspection and maintenance helps optimize its operation.
This document provides an introduction to flame arrestor technology, including the history and operating principles of flame arrestors. It discusses how Sir Humphry Davy discovered the principle of blocking flame propagation through narrow passages in 1815. Modern flame arrestors operate on the same principle, removing heat from the flame as it attempts to pass through narrow passages. The document outlines the different types of flame arrestors, how flames propagate when unconfined versus confined, and the development stages a confined flame can reach.
This document discusses performing a heat and mass balance (HMB) study on a cement plant. The objectives are to assess energy consumption, improve thermal efficiency, and identify areas of thermal losses. The study involves defining system boundaries, inputs, outputs, and performing mass balances. A case study on an ABC plant is presented where the overall mass balance was calculated based on measured input and output streams like kiln feed, fuel consumption, cooler vent air, and clinker production. The results can be used to optimize the pyroprocess and thermal energy usage.
Pneumatic conveying system of fly ash in a thermal power plantSoumyodeep Mukherjee
Fly ash is a byproduct of coal combustion that is captured by pollution control devices before being released into the atmosphere. There are two main types of fly ash removal systems - hydro sluicing and pneumatic conveying. Hydro sluicing uses large amounts of water and storage area and results in ash that cannot be used. Pneumatic conveying transports fly ash in a vacuum or with compressed air through pipes. The design of a pneumatic conveying system depends on accurate input parameters, component performance data, and theoretical calculations to reliably and efficiently transport fly ash from collection points to storage silos.
This document discusses fan concept and analysis in the cement industry. It provides information on static pressure, system resistance, gas properties, density correction factors, barometric pressure, and pitot tube measurements. It also discusses fan classifications, differences between fans and blowers/compressors, major process fans, system curves, fan laws, factors affecting fan performance, and calculations for fan efficiency, head, power savings, and damper losses. Case studies are presented on ESP exhaust fan retrofitting opportunities to increase efficiency.
The main objective of this presentation is that how to optimize the mill in pet coke grinding and what modification is required when changing from normal coal to pet coke.
ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILNISA Interchange
This paper highlights the efforts taken by the author in developing an Energy Model for the pyro-processing of Clinker production in a dry-process rotary cement kiln. In this paper this Energy Model is applied to a state of the art cement plant in a Far East Asian country. However this Energy Model is also applicable to all the modern dry process cement kilns. This model is based on actual field input data and site observations.
This document discusses ash handling systems for coal-fired power plants. It describes the types of ash generated - bottom ash and fly ash - and the difficulties in handling ash, which can be hot, cause dust and air pollution, and corrode equipment. The key requirements for effective ash handling systems are conveyed. Various ash handling system types are then outlined, including manual wheelbarrows, mechanical systems like bucket elevators and conveyors, and pneumatic conveyor systems. Final ash disposal and reuse options are also summarized.
Download Link (Copy URL):
https://sites.google.com/view/varunpratapsingh/teaching-engagements
This PPT contained slides for Steam distribution system, which is a third unit in Energy Conservation subject of final year in Mechanical Engineering Branch.
The content of PPT are mentioned below:
Steam Distribution System, Thermodynamics, Heat, Properties of steam, steam, steam system, PDRS, Steam pipe installation, Dryers, Operation and maintenance of steam traps, Condensate Recovery System, Flash Recovery System, Energy Conservation Opportunity in Steam Distribution System.
Cements Ground in the Vertical Roller Mill Fulfil the Quality Requirements of...LOESCHE
The document discusses concerns that cements ground in vertical roller mills may not meet quality requirements for the market. It summarizes that testing over the past 15 years has shown these concerns to be unfounded, as the quality of cement from vertical roller mills is as good as or sometimes better than cement from ball mills. The key areas of previous concern - water demand, strength development, and setting times - have all been shown to meet market standards for cement ground in vertical roller mills.
This document summarizes the key aspects of a dust suppression system. It discusses the types of dust generated in industrial processes and why dust control is necessary to protect health, safety and equipment. It then outlines the main approaches to dust control, including dust collection systems, wet suppression using water sprays, and airborne dust capture. Specific considerations for configuring an effective wet suppression system are covered, such as nozzle selection, droplet size and spray pattern.
NOx SOx CO2 and Urea Dust Control inFertilizers Plants.pdfPremBaboo4
NOx, SOx & CO2 emission are the serious problem in any fertilizers plant. The urea production and use of nitrogen fertilizers lead to the release of SOx, CO2, N2O and CH4, which are among the most important global GHGs. The synthesis of ammonia, from which all synthetic fertilizers are produced, accounts alone for about 0.8% of the global GHG emissions and 2% of global energy. CO2 emission factor from urea is 0.2 kg Carbon per kg urea, which is equivalent to the mass percent of Carbon in urea. Urea dust control system should be there in every plant. The pollution point of view urea dust is very harmful to buildings and humans. If you install CO2 recovery system, then you can also control SOx and NOx. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.
The document discusses the basics of dedusting filters used in cement plants. It covers key principles such as the formation of dust cake on filter bags, design guidelines for filtration velocity and air-to-cloth ratios, selection criteria for filter bags, and components of a dust collection system including equipment to be dedusted, dedusting pipes, filters, fans and insulation. Guidelines are provided for hooding, air velocities, dust concentrations and other parameters to ensure trouble-free operation of dedusting plants.
The document summarizes the design of a new pollution control equipment system for an industrial facility. The existing system was found to have low efficiency and high dust emissions. The new bag filter-based system was designed to have higher cleaning efficiency of 99% and meet latest emission standards. Key aspects of the new system design included larger suction hoods, larger diameter ducts and fans, additional instrumentation, and a taller stack. Recommendations were also provided to further improve occupational hygiene.
This document summarizes the design of an air conditioning system for Al-Zayan Mall in Alexandria, Egypt. The mall has 3 basement floors, 4 floors of retail space, and 6 floors of administrative offices. The design involves calculating the cooling load using the HAP program, selecting appropriate air handling units and fan coil units from manufacturer catalogs based on the load results, and designing ductwork using the equal friction method. Key components of the chilled water system are also described, including water chillers, cooling towers, pumps, and the water distribution system. Duct material, thickness, insulation, installation and testing are discussed.
There are several methods for measuring and sampling dust in foundries where workers are exposed. The most accurate method is the thermal precipitator, which uses an electrically heated wire to deposit dust particles from air onto glass slides that are then examined under a microscope. However, this process is tedious. The Owan's jet counter and Konimeter provide samples but have limitations such as small sample size or inconsistent results between operators. The Hexhlet sampler draws air through stages to collect coarse and fine particles on a paper filter that is weighed to determine dust concentration. Visual methods like the Tyndall beam or smoke generation can also be used to see dust levels. Key dust generation points in foundries include furnace work, sand preparation, core
The document describes a project report submitted by three students for their Bachelor of Engineering degree. The project involved designing a dust collector system to remove carbon dust particles. It includes sections on the introduction, which discusses boilers and dust collectors, methodology outlining the design and working principles, design procedures for the dust collector components, and a conclusion on the scope for future work.
Wet scrubbers are air pollution control devices that remove particles and gases from industrial exhaust streams. They work by introducing the dirty gas stream into a scrubbing liquid, usually water, where the gases and particles are collected. There are different types of wet scrubbers that vary in their complexity and method of operation depending on factors like the industrial process conditions and nature of pollutants. The document then provides details on the features, designing procedure, working principle, types, advantages and disadvantages of wet scrubbers.
1. The document describes a process to remove moisture from off-gas containing NOx and SOx from a zirconium oxide plant. The wet cake is dried, producing 450kg/hr of water vapor and visible plume from the stack.
2. A pilot plant test showed condensing 130kg/hr of the off-gas produced 3.55kg of condensate in 1 hour, indicating a condenser could capture around 460kg/hr. The document then details the design of a shell and tube condenser to remove the moisture.
3. The condenser design was based on pilot plant results and aimed to reduce the visible plume from the stack while meeting regulatory standards. Modeling
TSE Two Square Ecotechnologies provides air pollution control and management systems for industrial applications. It designs and manufactures systems like dust extraction, fume scrubbing, and ventilation using fabric filter bag houses. Bag houses remove dust from industrial processes in sectors like cement, steel, and mining. TSE bag houses use pulse jet or reverse air cleaning and come in online, offline, and insertable configurations for applications across industries. TSE has successfully installed systems for many Indian companies.
The document discusses various air pollution control technologies including particulate and gaseous pollutant control methods. It describes the basic approaches of pollution control through dilution or confining pollutants. Control equipments discussed include combustion, absorption, and adsorption methods for gaseous pollutants as well as mechanical, wet scrubbing, filtration, and electrostatic precipitation methods for particulate pollutants. Key pollution control objectives are outlined as prevention of nuisance, damage, and health hazards while improving product quality and minimizing economic losses.
Fabric filters are air pollution control devices that remove particulate matter from gas streams using filter bags. They work by having gas pass through filter bags, causing particulate matter to collect on the inner surfaces of the bags. There are several cleaning methods for fabric filters including mechanical shakers, reverse air, and reverse pulse jets. Proper selection of filter media and regular cleaning are important for effective particulate removal while avoiding issues like bag ruptures or pressure drops. Fabric filters are commonly used in industries like metallurgy, cement production, and ceramics manufacturing.
This document provides specifications for renovating and upgrading two dust extraction systems. Key points include:
- The systems will include bag filters, cyclones, centrifugal fans, ducting, and other components to collect dust from machinery and exhaust clean air.
- The bag filters must be capable of handling 20,000 cubic meters per hour and have components like filter bags, manifolds, and pulse valves.
- The ducting design must meet standards for materials, supports, and velocities to efficiently convey dust to the filtration equipment.
- The upgraded systems must limit worker exposure to respirable dust and ensure stack emissions do not exceed regulatory limits.
Roots Enviro Systems is an environmental engineering company focused on industrial ventilation and air pollution control systems. The company offers innovative products and turn-key solutions for applications across various industries. These include natural ventilators, scrubbers, biofilters, ducting systems, and baghouse filters. Roots Enviro has collaboration with German companies for scrubber and biofilter technologies.
Wet scrubbers are effective air pollution control devices that remove particles and gases from industrial exhaust streams using a scrubbing liquid, typically water. They operate by introducing the dirty gas stream into a chamber where it contacts the scrubbing liquid. Particulates and gases are then collected in the liquid. Wet scrubbers can be designed to collect particulate matter, gaseous pollutants, or both. They have advantages like small space requirements and handling high temperature gas streams, but also disadvantages like corrosion problems and high power requirements.
This document describes and compares four common particulate control devices: settling chambers, electrostatic precipitators, bag filters, and cyclones. Settling chambers use gravity to remove larger particles by passing gas through a long, rectangular chamber. Electrostatic precipitators ionize particles and capture them on oppositely charged plates, achieving over 99% collection efficiency. Bag filters use fabric bags to trap particles in a dust cake, while cyclones use centrifugal force to separate particles from gas in a vertically-mounted cylinder. Each device has advantages like low cost or efficiency, and disadvantages like size, temperature, or particle size removal limits.
The document discusses various types of air cleaning devices and air filtration equipment. It describes the factors to consider when selecting dust collection equipment, such as contaminant characteristics and gas stream properties. The main types of air cleaning devices covered are dust collectors, electrostatic precipitators, fabric collectors, wet collectors, dry centrifugal collectors, and air filters. Key aspects of each type are defined, including their collection mechanisms, advantages, and problems. Requirements for equipment handling radioactive or toxic materials are also outlined.
Venturi scrubbers are a type of wet scrubber air pollution control device that uses the venturi effect to inject liquid into a high velocity gas stream. They consist of a converging section, throat, and diverging section. Polluted gas enters the converging section and accelerates through the throat where it is mixed with an injected liquid, removing pollutants. Droplets are then separated from the cleaned gas. Venturi scrubbers can effectively remove particles and some gases, have small space needs, and handle high temperature streams, but require high power and can cause corrosion and water disposal issues.
This document summarizes research conducted to lower respirable dust levels at an iron ore grinding and concentrator plant through improved ventilation practices. The research involved 3 studies over 3 years. The greatest impact came from changing the ventilation profile throughout the facility using roof fans. Specifically, redirecting airflow lowered dust levels in the primary grinding area by 31%. Another successful modification was improving sealing of a reclaim tunnel and barricading access, which minimized dust transport through the tunnel into the plant. The results show ventilation improvements can significantly lower respirable dust concentrations in iron ore processing facilities.
This document summarizes the key components and design considerations of a robotic vacuum cleaner. It discusses how vacuum cleaners use pneumatic transport principles to move dirt and debris by entraining it in a high-velocity air stream. The design focuses on generating high airflow through the use of a centrifugal blower and short, wide-diameter tubing to connect the nozzle to the blower with minimal flow resistance. Performance is characterized by measuring the suction pressure and airflow under different load conditions to evaluate the cleaning capability.
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2. Content
Literature review
Identification of problem
Emission of dust and chemicals
What is De-dusting system
Calculations
Fan Efficiency
RMHS System
Checking of the ID fan capacity
4. Literature review
Development in the dust reduction technique have been done by many
engineers and how to reduce the dust from the plant is continuously
improving.
At first the dust from the foundries and the steel industries were removed
or minimized with the help of the exhaust fan or blower or huge fans.
And with this the development of the bag filter dust collection carried out,
with day by day increasing the demand for higher efficient dust removal.
5. Literature review
This system works on the basis of bag filter dust collection, where the
induced draft fan Is used for the suction of the dust from various dust
generating points.
The different points are provided for the suction of dust and the
header and the suction pipe from the main point is connected to the
header and thus that dust than goes to the bag filter dust collection
chamber.
Now when the dust and the fine particles are there in the chamber then
there are different filter bags provided in which the long cage around
2500 mm length is there.
6. Literature review
The cage is provided with the fiber cloth mostly
used material is P.T.F.E (polytetrafluoroethylene)
whose resisting temperature is 326.8 °C.
Now when dust enters the chamber then it goes to
the filter bag and sticks there.
below these bags the hoper section is there and
beneath the hopper there is valve which discharges
the dust and the other particles.
7. What is De-Dusting System.
The De-dusting system works on the basis of the induced draught
fan.
The ID fan is connected with the ducting system.
The ducting system/header is generally 250-300 mm diameter
pipe and that is connected through the different suction points.
The different suction points are the one which are situated over
the different discharge points over there the raw material is
discharged.
Further the ID fan outlet is connected through the chimney for
the exhaust of gases to the atmosphere.
8. Identification of problem
The process discussed above is for BF2 and the same process is for BF1 but
the RMHS system is open to atmosphere for BF1.
In BF1 the material from ground is discharged to the RMHS building which is
at 4th floor (12.58m) height.
The raw material is discharge at top floor through belt conveyor.
The building consist of 4 big hopper and these hopper consists of different
raw material according to the requirement of every day.
The hopper generally 2 hopper of COKE and other two are iron ore.
9. Identification of problem
The material is discharged at the top floor and that contains the shuttle
trolley.
The trolley is moved according to material onto which it is to be
discharged.
At the time of discharge the dust which is generated from the material
when it falls is very high and the visibility is zero at this time.
And due to this the discharge is done at morning, then at noon, and at
night.
10. Emission of dust and chemicals
Picture of RMHS Dust and Chemical emission while
charging the material in Hopper
11. Identification of problem
And when the hopper is fully filled then it is further discharge through
the vibro-feeder which is at 2nd floor and due to vibration the dust and
chemical emission is very high and technician can not stand near
there.
Beneath the vibro-feeder there is screen which separates the undersize
and oversize material and the required size material to the bottom
conveyor which is ground floor.
And the fines are generated so that is discharged to the fines centre
which is done through conveyor (the dust from the fines is also high).
13. Identification of problem
Now as discussed earlier the two hopper are for Coke.
And the coke is preheated for this the section is made in the coke hopper
section and the hot air at temperature of 250 degree Celsius.
And which is running 24 hrs due to this the dust and fines of coke are
generated very high and the temperature is very high at this time.
So this is the problem which is required to minimized or controlled.
After discussing this problem with concerned guide in industry we have
decided to develop the De-dusting system for the raw material handling
system for BF-1 plant.
14. Different Components of De-Dusting
System
1. Bag Filter
2. Header (Pipe)
3. Chamber containing Bag Filter
4. Chimney
5. Centrifugal fan/ Induced Draft Fan
6. Butterfly valve
15. The working principle of bag filter
Dust contained gas will enter into the upper side path hopper.
In the screen board action of air flow up, reduce the flow
velocity the part of the big particle inertia force due to the role
of dust be separated into hopper.
Dust contained gas enters into the bag filter in the filtration
purification, dust sticks in the outer surface of the filter bag.
As the filter bag dust surface increases and filter import and
export with differential pressure rise.
16. The working principle of bag filter
As the filter bag dust surface increases and filter
import and export with differential pressure rise.
Pulse is a key components of pulse bag filter. Its
service life is the user of the concerns of problems.
18. Calculations.
The darcy-weisbach equation is used for calculating the pressure loss in a
cylindrical pipe of uniform diameter D,
ΔP =Pressure Drop.
F =Pipe friction Co-efficient.
L =Length of pipe
V =Mean Velocity.
D =Pipe Diameter.
ΔP= flV2 /2gd.
19. Calculations.
f =2.738
L =20.650 m
V = 30 m/s (taken by organization)
D =0.3 m
ΔP = 8645.214 Pa
ΔP = 0.0864 bar
ΔP = 2.738 x 20.650 x (30)2 /2 x 9.81 x 0.3
20. Calculations.
Now, the capacity of ID fan which is there in the Electrotherm is 20,000 Nm3/hr
The fan power requirement is to be calculated
P = dp x q
Now,
P = 0.5 x 10 5 x 5.555
P = 277,777.77 (W)
P = 277.77 (kW)
Where
Pi = power consumption (W)
Dp = total pressure loss (Pa)
Q = air volume flow (m3/s)
21. Calculations.
The motor HP required is obtained from the manual of the supplier
[Rajdeep Engineering] is 40HP motor.
22. Fan Efficiency
μf = dp x q / P
μf = 0.958 or 95.8 % efficiency.
Where,
μf = fan efficiency (0-1)
Dp = pressure (Pa)
Q = air volume delivered by fan (m3/s)
P = power used by the fan (W)
μf = 0.5 x 105 x 5.55/ 277.77 x 103
24. Checking of the ID fan capacity.
There are in all 11 suction points from where the air and dust is to be
sucked and they are not operating at the same time.
Thus, the calculation is based on that, the simultaneous operation is 4
suction points at the same time.
The suction points are as follows. Two at the top of the storage
building from where the charging is done i.e. above the shuttle
conveyor trolley there will be 2 suction points. Below the trolley there
are 4 bunkers among them 2 bunkers are of coke and the other 2
bunker are of iron ore.
25. Checking of the ID fan capacity.
From the shuttle trolley the material is discharged in the
bunker and during this the dust emission is very high and so 4
suction points above the bunkers (these all are at 4th floor of
the building i.e. at 11m from the ground).
Then below that there is screen and vibrofeeder are installed
in this area the required size is sent to the conveyor no 3 and
the rest are sent to the fines conveyor which are under size
26. Checking of the ID fan capacity.
The vibro-feeder and the screen section is located at the 4.30m from the ground
and here also the dust emission is very high as the vibro-feeder shakes and
separates oversize and undersize material therefore the dust emission is very high
therefore here also 4 suction points are required to be given.
Below that there is belt conveyor in which the material is discharged and that
material goes to the belt no 4 this material is sent to the Blast furnace-1 and is
discharged at the top of the furnace.
And when the material is discharge in the B.C-4 then there is also emission of dust
thus there also the suction point is to be give therefore in all total 11 suction
points are provided.
27. Checking of the ID fan capacity.
(velocity is assumed to be 25 m/s)
Area= 3.14 x (0.3)2/4 (m)
Area= 0.07065 m2
Now,
Q= Area x velocity
Q= 0.07065 x 25
Q= 1.766 m3/s
And the calculated Q= 6358.5 m3/hr.
28. Checking of the ID fan capacity.
Area= 0.8 x 1
Area= 0.8 m2
And calculated Q= 2880 m3/hr.
29. Checking of the ID fan capacity.
Therefore, the total simultaneous suction points are (Volume flow rate)
Q= 6358.5
+ 2880
+ 6358.5
+ 2880
Thus the required ID fan capacity i.e. 20,000 Nm3/hr. is justified.
Total = 18,477 Nm3/hr.
35. Summary and future work
Timeline Of work
STARTDATE END DATE DESCRIPTION
1-4-17 1-15-17
Industry Visit/ Working
process
11
1-16-17 1-31-17 Project title finalise 15
2-1-17 2-15-17 Literature Review 14
2-16-17 2-28-17 Analyzed the Process 12
3-1-17 3-15-17 Developm ent of De-dusting 14
3-16-17 3-31-17
Design and analysis of the
system
15
4-1-17 4-15-17 Bill of Material 14
4-16-17 4-30-17
Sanction of BOM/ Thesis
w rititng
14
5-1-17 5-15-17 Final subm ission 14
DURATION
(days)
Design of De-dusting System
36. Summary of work
After the first review the calculations and the required
consideration for the De-dusting system have understood
and concerned with the Internal guide about the things to
consider for this system.
Then the calculation of pressure drop and required fan
capacity were carried out.
After doing the calculation then according to the values
the design consideration the layout of De-dusting System
is made.
37. Future Work
The organization Electrotherm Steel and Engineering
India Ltd. have given assurance that they have
accepted the design which I have made after
considering various parameters and based on that
design they are finding the supplier and the company
who can fabricate this De-Dusting System.
38. Future Work
The company have finalized the design and when I
visited to the company the Mechanical Department
of the Blast Furnace plant were deciding when to
start the work on De-Dusting System for Blast
Furnace-1 for Raw Material Handling System. The I.D
fan Capacity is finalized and how much dust will be
there in the air after this implementation of this
system that work is in progress.