Nett Technologies Inc's 2013 Mining Diesel Emissions Council (MDEC) presentation
STM Environment
1. Advanced Gas Cooling, Dry Grinding,
Feeding & Injection Technologies for
the Environment
1
Experience is our Technology℠
Experience is our Technology℠
2. Co-Developer of Sodium Dry Injection Technology
Market Leadership
‣ In the 90s, STM led the
world in dry grinding for
gas cleaning applications
by co-developing a novel
gas cleaning approach
with a world-leading
chemical supplier.
‣ The system uses ground
Sodium Bicarbonate for
cleaning hot exhausts.
2
STM Serial No. 1.
Reggio Emilia, Italy
3. Continuing R&D
Market Leadership
‣ There is no company with
more mills installed on
Sodium-based gas
cleaning systems.
‣ Today’s STM is regarded as
the premier supplier for
grinding Sodium-based
reagent with the most
advanced milling know-
how and the most accurate
weigh-feeding systems.
3
STM Serial No. 207.
The Latest Design
4. Injection Know-how
Experience
‣ STM EcoSystems division
may be small, but we
boast personnel with over
100 years of combined
experience in gas
treatment systems.
‣ We utilize this experience
and the latest
computational models to
correctly predict system
performance.
4
CFD Examples of
Reactor Designs
0.0 12.0 24.0 36.0 48.0 > 60.0
Total Velocity (ft/s)
Airflow Scienc
Corporation
Design 3 Option 1 Model Results
Total Velocity - Centerline Front Elevation Throat Zoom
Bold Eco - Infratech Reactor Modeling Ju
Figure4
L-14-BEX-03-1
0.0 15.0 30.0 45.0 6
Velocity Magnitude (ft/s)
Velocity Magnitude - All P
Side View - Model Doma
BoldEco - Versa Maps Filter Modeling
Figure3
L-13-BEH-02
8. Optimal System for Each Application
Gas Cleaning Systems
8
Combustion Process
System Type and Typical Reagent
Grinding System Dosing and Injection System
Technical Grade
Sodium Bicarbonate
Trona
Activated
Carbon
Ready to Use
(Lime,
Limestone, etc.)
Sodium
Bicarbonate +
Activated Carbon
Industrial and Hazardous
Waste Incineration
• • • •
Biomass • • • •
Cement • • •
Power • • •
Water Treatment • • •
Metals Recovery Furnace • • • •
Cremation • • • •
General Combustion: Heavy
Fuel Oil and Natural Gas
• • •
Municipal and Hospital
Waste Incineration
• • • •
Steel and Foundries • • • •
Glass • • •
12. The Basic JCF Design
STM JCF Hammermill
‣ Full-feature classifying mill coupled to
a transport air fan.
‣ Ideal for single-point gas cleaning
plants and for retrofit applications.
‣ Operational advantages:
‣ Maximum energy efficiency
‣ Low noise emissions
‣ Minimal maintenance needs
‣ Compact, small space requirement
‣ High reliability and quality
‣ Ease of maintenance
12
Basic JCF Mill
13. Equipment Specifications and Capacity
Technical Data JCF Mills
13
Model
Installed
Power
Absorbed
Power
Capacity* Air Flow Pressure Noise
Type/Size kW kW Range kg/h m3/h mm H2O dbA
JCF 300 18.4 16.6 10-250 800 500 <75
JCF 400 29.2 26.3 40-450 1500 800 <75
JCF 630 64.2 57.8 100-1000 2700 800 <75
JCF 800 98.0 88.2 100-1400 4700 1000 <75
JCF 1000 129.0 116.1 100-1800 6000 1000 <75
JCF 1250 205.0 188.7 120-2925 9750 1000 <75
JCF 1500 284.0 261.2 150-4050 13500 1000 <75
*Capacities Stated for Sodium Bicarbonate
18. JCFF Series Mill for Indirect Dosing
JCFF Indirect Injection Mill
‣ Full-feature classifying mill coupled
to a transport air fan and a filter/
receiver.
‣ Ideal for complex gas cleaning
plants with multiple injection points.
‣ Operational advantages:
‣ Modular and flexible arrangement
‣ Stockpile applications possible
‣ Ideal for multi-injection points
‣ Useable with multiple dosing systems
‣ Replaces multiple mills for cost savings
18
JCFF Mill
A - Dosing System
B - Mill
C - Filter/Reciever
D - Suction Fan
20. JCFF Series Mill with Multiple Dosing Units
JCFF Indirect Injection
20
JCFF w/Multiple Dosers
A - Dosing System
B - Mill
C - Filter/Reciever
D - Suction Fan
E - Rotary Valve
F - Double Dosing System
G - Eductor Venturi
H - Regenerative Blower
I - Mill to Filter Duct
L - Filter to Fan Duct
M - Air Recycle Loop
N - Injection Point Piping
31. Dual System on Dry Injection System
BicarMill Installation
31
32. Self-classifying, Compact Design
STM Compact Mill
‣ Compact, self-classifying mill coupled to
a transport air fan. The self-classifying
design makes it a good choice for
applications where particle size is not
critical or where sorbent stoichiometry or
acid gas efficiency requirements are low.
‣ Ideal for medium/small gas cleaning
plants and for low-cost retrofit
applications.
‣ Operational advantages:
‣ Low energy consumption
‣ Minimal maintenance needs
‣ Compact, small space requirement
‣ Ease of installation
‣ Automatic operation
32
Compact Mill
33. Equipment Specifications and Capacity
Technical Data CompactMill
33
Model
Installed
Power
Absorbed
Power
Capacity* Air Flow Pressure
Energy
Req.
Noise
Type/Size kW kW Range kg/h m3/h mm H2O kW/Ton dbA
Compact 280 18.4 14.8 5-40 800 500 60-100 <75
Compact 400 29.2 23.5 10-120 1500 800 55-85 <75
Compact 600 64.2 51.5 20-450 2700 800 52-85 <75
*Capacities Stated for Sodium Bicarbonate
38. In-line Material Crusher with Online Maintenance
MF Lump Breaker/Crusher
‣ Compact, in-line clinker crusher/
delumper with online maintenance
capabilities.
‣ Capable of crushing a full-size clinkers
down to 1” particles.
‣ Can be installed upstream of dust
airlocks and conveying systems in
boiler and just collector applications.
‣ Operational advantages:
‣ Low energy consumption
‣ Inline maintenance - no need for removal
‣ Compact, small space requirement
‣ Ease of installation
‣ Heavy-duty construction
38
MF Series Lump Breaker
39. In-line Material Crusher with Online Maintenance
MF Lump Breaker/Crusher
39
Unit Deactivated for
Maintenance
Unit Online and
Operational
40. Metering & Weigh Feeders for Gas Cleaning Applications
STM Dosing Systems
40
MDS AC – 50
41. High-Accuracy Powder Metering Technology
STM Weigh-Feeder Systems
‣ Solves the problem of accurately metering free-
flowing powders by monitoring the flow of sorbents
and activated carbon into the gas stream.
‣ Can be used for any application that uses powders,
such as dry scrubbers and duct injection systems.
‣ Accuracy twice that of competitive commercial
units.
‣ Operational advantages:
‣ Maximum energy efficiency
‣ High accuracy
‣ Minimal maintenance needs
‣ Compact, small space requirement
‣ High reliability and quality
‣ Ease of installation
41
Micro-Dosing Unit
42. Elements of Our Metering Systems
Volumetric Components
‣ Modular dosing system elements allow the
interchange of different elements to
achieve different injection rates
‣ Variation of the dosing screw design based
on the type of material being metered:
‣ Type A: Solid metering screw for non-
compressible, high specific gravity material
‣ Type B: Open (spring) metering screw for
compressible, low specific gravity material
42
Type B Spring ScrewType A Solid Screw
Agitator Element
43. Elements of Our Metering Systems
Control Components
43
Integral
Air Preparation Unit
Surge Hopper
Level Sensor
Transport Air
Flow Meter and
Pressure Transducer
Weight Scale
With Vibrator
High-accuracy
Gear Reducer
8400 Hour
NON-STOP GUARANTEE
45. Compressed Air Propelled Metering Systems
MD-AC MicroDoser
45
Compressed Air Micro-Dosing Unit
MD-AC Doser
1 - Dosing Housing
2 - Hopper
3 - Inlet Feed Port
4 - Metering Port Exhaust
5 - Metering Screw
6 - Level Sensor
7 - Doser Gear Reducer
8 - Agitator Gear Reducer
9 - Vibrator
10 - Agitator Element
11 - Vibrating Fork Level Sensor
12 - Surge Hopper
13 - Eductor Venturi
14 - Pressure Transmitter
15 - Weighing System
16 - Air Preparation Station
17 - System Platform
46. Compressed Air Propelled Metering System Material Flow
MD-AC Doser Schematic
46
Weigh Scale
Venturi Eductor
Material Inlet
Surge
Hopper
Transport Pipe
47. Elements of MD-AC Metering Systems
Propulsion Components
47
Anti-plugging
Pressure Sensor
Compressed Air
Level Sensor
Venturi Eductor
Surge
Hopper
Stainless Steel
Transport Pipe
and
Anti-abrasion Tube
48. Blower Propelled Metering Systems
MD-P MicroDoser
48
Blower Propelled Micro-Dosing Unit
MD-P Doser
1 - Dosing Housing
2 - Hopper
3 - Inlet Feed Port
4 - Metering Port Exhaust
5 - Metering Screw
6 - Level Sensor
7 - Doser Gear Reducer
8 - Agitator Gear Reducer
9 - Vibrator
10 - Agitator Element
11 - Vibrating Fork Level Sensor
12 - Surge Hopper
13 - Eductor Venturi
14 - Pressure Transmitter
15 - Weighing System
16 - Air Preparation Station
17 - System Platform
18 - Blower
49. Blower Propelled Metering System Material Flow
MD-P Doser Schematic
49
Weigh Scale
Venturi Eductor
Material Inlet
Surge
Hopper
Transport Pipe
50. Elements of MD-P Metering Systems
Propulsion Components
50
Anti-plugging
Pressure Sensor
Level Sensor
Venturi Eductor
Surge
Hopper
Stainless Steel
Transport Pipe
and
Anti-abrasion Tube
Venturi Eductor
Surge
Hopper
Blower
52. Flow-through Valve Metering System Material Flow
MD-VS Doser Schematic
52
Weigh Scale
Flow-through
Valve
Material Inlet
Surge
Hopper
Transport Pipe
53. Elements of MD-VS Metering Systems
Propulsion Components
53
Level Sensor
Stainless Steel
Transport Pipe
and
Anti-abrasion Tube
Flow-through
Rotary Valve
Surge
Hopper
Blower
Flow-through
Rotary Valve
54. Double Metering Systems
MD-D MicroDoser
54
Dual Micro-Dosing Unit
MD-D Doser
1 - Dosing Housing
2 - Hopper
3 - Inlet Feed Port
4 - Metering Port Exhaust
5 - Metering Screw
6 - Level Sensor
7 - Doser Gear Reducer
8 - Agitator Gear Reducer
9 - Vibrator
10 - Agitator Element
11 - Vibrating Fork Level Sensor
12 - Surge Hopper
13 - Eductor Venturi
14 - Pressure Transmitter
15 - Weighing System
16 - Air Preparation Station
17 - System Platform
55. Double Metering System Material Flow
MD-D Dual Doser Schematic
55
Weigh Scale
Material Inlet
System 2System 1
56. Water Propelled, Slurry Mixing Metering Systems
MD-A MicroDoser
56
Water Propelled Micro-Dosing Unit
High-pressure Pump
Peristaltic Pump
MicroDoser Venturi
57. Water Propelled, Slurry Mixing Metering Systems
MD-A MicroDoser
57
Material Inlet
High-pressure Pump
MicroDoser Venturi Transport Pipe
Flow Accelerator
66. Multi-Outlet Material Distributors
Material Distribution Systems
66
‣ Solves the problem of discharging and
distributing hard to flow material from a
single silo to multiple points.
‣ Design is adaptable to the number and
location of outlets, as well as the speed of
the material extraction.
‣ Operational advantages:
‣ Modular design
‣ Optimal material distribution
‣ Multiple outlets with single silo
‣ Ideal for hard to handle powders
‣ Minimal maintenance needs
‣ Compact, small space requirement
‣ High reliability and quality
‣ Ease of installation
70. What is Evaporative Gas Cooling?
STM Atomizing Systems
‣ When a cold liquid is sprayed into a hot gas, the following phenomenon
occurs:
• The liquid droplets absorb heat from the hot gas, thus raising the temperature of the
droplets
• As the droplets are heated, they begin to vaporize, and decrease in diameter until they
are totally vaporized
• The evaporated liquid (steam) then continues to absorb heat from the gas until
equilibrium is reached (gas and steam temperature is equal)
‣ This transformation of the cold liquid droplets into steam is
accomplished by absorbing heat from the hot gas, thus reducing its
temperature.
‣ Although a portion of the heat given up by the hot gas is used to heat the
water droplets and the vaporized steam, the largest portion of the heat
removed from the gas is utilized to provide the “latent heat of
vaporization” required to vaporize (evaporate) the droplets.
‣ This phenomenon is generally known as Evaporative Gas Cooling
70
71. Evaporative Gas Cooling Processes
STM Atomizing Systems
‣ Evaporative gas cooling, also known as EGC, is utilized to
“condition” flue gas from a combustion process so that it is most
effectively treated in downstream dust collection systems.
‣ Examples of process exhausts which require gas cooling include:
• Dryers in chemical and pharmaceutical processes
• Furnaces in steel and non-ferrous metals
• Power generation for humidification of the gases upstream of an ESP
• Power generation for optimization of a DSIACI system
• Waste incinerators (Municipal and Hazardous)
• Kilns in the cement and lime industry
‣ Gas conditioning is used when the gas needs to be cooled to a
temperature/moisture condition that is safely above the dew-
point of the gas, in order to avoid moisture condensation.
71
72. EGC Benefits Upstream an ESP
STM Atomizing Systems
‣ Evaporative gas conditioning is used upstream of an
Electrostatic precipitator to improve performance.
‣ EGC increases performance of an ESP:
• Reduces particle resistivity
- Increasing current density
• Decreases gas viscosity
- Increasing migration velocity
• Increases dust cohesivity
- Reducing rapping re-entrainment
• Decreases gas volume
- Increasing treatment time
72
73. EGC Benefits Upstream an ESP
STM Atomizing Systems
‣ Evaporative gas conditioning is used upstream a fabric filter or
baghouse.
‣ EGC increases performance of a fabric filter:
• Reduces gas temperature
- Avoiding damage to the bags
- Permitting the use of a lower temperature rated bag
• Increases dust cohesivity
- Improves the filter cake properties
- Reduces filter drag
- Reduces filter penetration (bleed-through)
• Decreases gas volume
- Lowers the air-to-cloth ratio (filtration velocity)
73
74. EGC Benefits Upstream an ESP
STM Atomizing Systems
‣ There are numerous applications where EGC can benefit a particular process
other than just particulate collection.
‣ Processes that benefit from EGC:
• Dioxin/Furan control
- Rapidly quenching the gases prevents formation of dioxins and furans
- Reduces the amount of or eliminates the need for activated carbon injection
• Acid gas control
- Approach to saturation increases the efficiency of calcium-based dry sorbent injection for
SO2 and HCl
- Reducing the temperature increases the efficiency of calcium-based dry sorbent injection
for SO3 removal
• Mercury and heavy metals
- Reducing the temperature increases the efficiency of activated carbon
‣ Often a slurry system can be replaced by a dry sorbent injection system with
EGC assist.
74
75. Droplet Size Analysis
STM Atomizing Systems
75
Performance Comparison OptiVap vs. Nearest Competitor
Percentofdropletsunevaporated
0
25
50
75
100
Meters the droplet has travelled
0 1 2 3 4 5 6 7 8 9 10
OptiVap Nozzle
Competition
76. Droplet Size Analysis
STM Atomizing Systems
76
Maximum Droplet Size for Different Outlet Temperatures
DropletSize(µm)
0
45
90
135
180
Outlet Gas Temperature (Deg C)
250 200 150 100 75
Droplet Size (µm)
77. Advanced Dual-Fluid Atomizers
STM Atomizing Systems
77
OPTIVAP NOZZLE DESIGN
The OptiVap nozzle is a dual fluid atomizer that uses compressed air or nitrogen
to atomize a liquid, typically water, to cool or to inject a chemical into hot gas stream.
‣ Fine, uniform droplets under all conditions, even when water pressure
exceeds air pressure (cannot be overdriven)
‣ Lowest energy consumption of any nozzle on the market
‣ Used for high velocity gas streams with short residence time requirements
‣ Minimal maintenance needs, optimal for harsh duty environments
78. Dual Fluid Atomizers for Gas Cooling
STM Atomizing Systems
78
Explosion Doors
Nozzles after 6 months
of operation showing
no buildup and no wear
Spray lances with heat shields
and freeze protection
High Temperature Upflow
GCT for Steel EAF
79. Dual-Fluid Atomizers for Humidification & Chemical Injection
STM Atomizing Systems
79
Chemical Injection /Humidification
Spray Lances for Power Boiler Application
Spray Lance Headers
3-Zone Humidification Control System
80. Gas Cooling, Milling & Dosing Technologies for the Environment
STM EcoSystems
216 US Highway 206, Unit 21
Hillsborough, NJ 08844
Sales Contact: Joe Riley
Tel. 609.273.3331
info@stmecosystems.com
www.stmecosystems.com
80
Experience is our Technology℠
Experience is our Technology℠
