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Air Pollution

Control Systems

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ServingPower

and

IndustryIntroductionDedusting systems are installed in variousindustrial and utility applications either torecover valuable quantities of process mate-rial or to achieve low ambient dust emissions.Heavy industry in general has made valuablecontributions to ambient air quality in recentyears, in part to comply with environmentalprotection directives, in part to satisfy thedemands of local authorities and neighboringcommunities.

Electrostatic Precipitators (ESPs), tradition-ally regarded as acceptable technology forreducing dust emissions from dust producingsources, are typically found on various pro-cesses such as cement and lime kilns, utilityand recovery boilers, industrial and municipalwaste incineration plants, as well as pulp andpaper plants, among others. Still, many ofthese plants experience high dust emissionscaused by transitory process conditions,mainly due to the precipitators inability torespond quickly to the changing conditionsof the process.

These emissions are easily avoided withthe installation of add-on gas conditioningsystems or by replacement with a properlydesigned modern fabric filter dedusting sys-tem. However, the importance of provenexperience and process knowledge in the ap-plication of fabric filter dedusting plants or indevices to control the conditions at the inlet ofan ESP cannot be underestimated.

Choosing the right equipment type anddesign requires sophisticated methods ofselection as well as provisions for efficiently

operating those components, adapted to theprevailing construction, erection, operation,and environmental requirements. BoldEco pos-sesses in-house know-how and experience in theselection, application and operation of mostmodern air pollution control equipment com-ponents and can be relied upon to choose theoptimum solution from a variety of options.

After many years of advising, developingand supplying such plants to various heavy

MODERN CEMENT PLANTA modern cement plant is required to be environmentally friendly not only with respect toclean air and clean water it must be esthetically pleasing as well.

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industries, including power, we have foundthe proper complement of operational ex-perience, process knowledge and advancedanalytical tools, resulting in truly advancedand efficient systems designs.

BoldEco SolutionsSince BoldEco possesses in-house experienceto design, fabricate and erect complete gasmoving and dust collection systems, we are ina unique position to provide completely integrated,

single responsibility dedusting solutions.

Due to our vast collective experience in thefield of dedusting, our dust control technol-ogy is continually being updated to meetcurrent and future requirements, and, byimplementing newly developed technologicalimprovements, achieves elevated efficienciesat a high level of reliability.

BoldEco Environment has supplied both newand retrofit installations in response to thevarious regulations calling for increasinglyefficient dedusting plants, always conscious

of the customers need to cost-effectivelyachieve ever higher degrees of flexibility andreliability.

Project ExecutionProjects can be carried out accordingto a clients wishes, based on the supply ofsystem components only, on smart-parts andengineering for local fabrication and erection,or on complete turnkey projects, which maybe more desirable due to sole-source responsi-bility. Since BoldEco manufactures and installsthe main proprietary system components andlarge fabricated elements through cooperation

with local partners, there is complete controlover the entire project execution process.

Projects are executed by competent projectmanagers and engineers, who oversee theengineering, manufacturing and logistics. Asmuch as possible, BoldEco ships pre-assembledcomponents for ease of installation, as well asto maintain tight control over erection costsand installation schedules. Commissioning,acceptance testing and field service, com-pletes our customer service regimen.

BoldEco ExperienceTogether with our specialized partners andits competent affiliates around the world, webring valuable experience to each applicationdemanding a high degree of technical compe-tence in design and engineering. It is just thisspecialized knowledge, vast experience andbreadth of market coverage that allows us tocompete at a very high level internationally .

Already, a large number of systems are

successfully operating in steel, power gen-eration, cement, lime, incineration and otherindustries. BoldEco has proven that it cansuccessfully execute large-scale, complexprojects throughout the world and pledges tomaintain its reliable partnership with industryand power by its continued investment inmarket expansion.

Ancillary Equipment and SystemsBoldEco is skilled in supplying more than justparticulate filters. Our arsenal of technologiesincludes large process fans, general ventilationsystems, air-to-air heat exchangers, evapo-

rative gas cooling systems, SNCR DeNOxsystems, materials handling and transportsystems, DeSOx systems, both dry and semi-dry, including our patented LEC limestoneemission control system, particulate and gasscrubbers, as well as other innovative gascleaning technologies. Our equipment enjoysthe enviable reputation of being a good valuewhile providing all of the efficiency and reli-ability expected from a top quality air pollu-tion control system supplier.

Engineering and Customer ServicesBoldEcos in-house gas flow and sound

measurement tools, as well as its numericalmodeling software, such as ComputationalFluid Dynamics (CFD), acoustics, pressurewave propagation, etc., allows us to providetimely expert field and engineering services toour customers at a reasonable price.

As part of our customer service regimen, wehave qualified service and technical person-nel ready for a variety of field services or toprovide an on-site technical evaluation of anynew or existing pollution control application.

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CEMENT and LIME KILNS

Rotary Kiln Applications

Modern dry process cement kilns force hot

kiln gases through a raw mill to dry the

raw material, which is then recovered by a

dedusting plant. For preventive maintenance

purposes, a bypass is utilized to direct the gas-

es around the mill, directly into the dedusting

plant. In the case of a lime kiln or an older

design cement kiln, the process may be differ-

ent, but the gas cleaning plant has the same

performance requirements.

The dedusting plant has therefore to deal with

2 main gas conditions: 1) low temperature,

high dust laden gases exiting the raw mill

(combined operation); and 2) low dust load

kiln exhaust gases, cooled by water injection

in a conditioning tower or bleed in air (directoperation).

The transition between these two operating

conditions is especially difficult to handle with

an ESP due to rapidly changing dust electri-

cal characteristics. In those cases where the

ESP performance needs to be improved, the

installation of an efficient evaporative cooling

system is recommended.

The trend in recent years has been to replace

or upgrade a process ESP with a process fabric

filter. Various options in filtration fabrics areavailable today for installation in fabric filter

plants. These modern fabrics have proven

themselves capable of being exposed to vary-

ing moisture and temperature ranges as well

as to varying concentrations of dust.FABRIC FILTERwith forced air cooler

CEMENT KILN FABRIC FILTERGas flow: 540.000 m3/h - 317,647 AcfmFiltering surface: 10.000 m2 - 107,257 ft2

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INCINERATION GAS CLEANING

Incinerator Applications

Waste gases extracted from an incinerator

must be treated with a gas cleaning system to

remove the particulate by-products, as well

as neutralize all of the acid gases and remove

hazardous air pollutants.

In many cases, a waste heat recovery boiler

is installed after the incinerator (or secondary

combustion chamber), where any precursors

to Dioxins and Furans (D/F) combine due to

optimum formation temperatures.

A proven solution is the installation of an

Evaporative Cooling Tower or a Lime Spray

Dryer downstream of the boiler to rapidly

lower the exhaust gas temperature and re-

duce D/F formation, as well as remove any

acid gases, as in the case of a spray dryer.

In the case of a cooling tower, Activated

Carbon (A/C) is augmented by a Hydrated

Lime injection system, installed upstream of a

Fabric Filter in order to capture D/F, as well as

any Heavy Metals (HM) present in the gases.

The fabric filter can be fitted with special

membrane filtration bags (and in some cases

coated with catalysts or A/C) that correspond

to the operating conditions and therefore guar-

antee durability of the bags and a clean gas

content of less than 10 mg/Nm3.

A wet gas scrubber often follows the particu-

late, D/F and Heavy Metals collection train to

abate acid gases and to polish the exhaust gas

stream to in order to meet local requirement.

INCINERATOR GAS CLEANING SYSTEMIncluding Fabric Filter, Dry Acid Gas Scrubbing Reactor and Reagent Recycle System

VIEW OF SPRAY COOLERGood gas distribution is a must in any

GCT application

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STEEL AND METALLURGICAL APPLICATIONS

FOURTH HOLESettling chamber onan Electric Arc Furnace

Application

Steel Mill Applications

Fabric filters can be designed to withstand

high negative pressure, high temperatures

and high dust loads, such as those found in

the operation of steel mill furnaces.

A special filter design is available that pro-

motes uniform airflow distribution to ensure

that the dust is well distributed on the col-

lecting surfaces for properly balanced dust

extraction and to maintain low pressure drops

through the baghouse.

Bags utilized in steel mill Electric Arc Furnace

applications can be as long as 8 meters, em-

ploying traditional pulse jet technology.

BoldEco have numerous installations wherethe successful implementation of a spray

cooling tower has resulted in capital and

operational savings to the customer.

FABRIC FILTER

with axial cyclone

SPRAY COOLERon an Electric ArcFurnace Application

FILTERING GROUPwith fan and stack

CANOPY DUCTSon an Electric Arc

Furnace Application

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COAL FIRING SYSTEMS

Coal Mill Applications

Coal mill filters are installed in indirect firing

applications (when the coal is milled and then

fed to a burner in a separate step) in order to

better control the combustion characteristics.

In these cases, a coal collection filter must be

installed, and it must be designed to ensure

the prevention of coal dust accumulation and

an airtight housing.

The fabric filter housing is designed to

withstand explosive pressures and must be

equipped with a suitable number of rupture

disk diaphragms or explosion doors.

For a semi-direct firing system, our cyclones

are installed in the milling circuit in order to

separate the coal from the milling gases sothat they can be fed to the burner with a

separate fan, also furnished by BoldEco.

Our designs incorporate all of the latest explo-

sion suppression and protection techniques,

including our surge suppressor modules.

COAL MILL FABRIC FILTERGas flow: 40.000 m3/h - 23,530 Acfm

Filtering surface: 670 m2 - 7,212 ft2

Showing surge suppressor module tovent explosions to atmosphere

HIGH PRESSURE BURNER FANGas flow: 40.000 m3/h - 23,530 Acfm

EXPLOSION VENTSInstalled on the baghouse inlet

plenum according to specifications

CYCLONE FOR KILN FIRINGIncludes a surge suppressor module

that vents the explosion to atmosphereto avoid damage to process equipment

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BOILER APPLICATIONS

WASTE HEAT BOILER ESP2-field ESP on a waste heat

boiler application

Boiler Applications

In most boiler applications, it is still acceptable

to install electrostatic precipitators (ESPs) for

the collection of flyash.

ESPs tend to be more cost effective particulate

control devices if the ash collected is low in re-

sistivity, and if the resistivity remains constant

throughout the operational parameters of a

given installation.

BoldEco Environment is capable of supplying

the entire gas cleaning system for small boiler

applications, including multicyclones, ESP and

fan.

Our technology allows us to offer two ap-

proaches to electrode cleaning, a Europeandesign implementing tumbling rappers and

rigid frame discharge electrodes, as well as an

American disign, implementing MIGI rappers

and either weighted wire or rigid dischage

electrodes.

RAPPER CONTROLCABINETWall mounted rappercontrol cabinet can bemounted locally to ESPrapper location

TRANSFORMER/RECTIFIER SET

Automatic VoltageController mouned

directly onto T/R set

AVC CABINETInside vew of a typical AVCcontroller cabinet

AVC LINEUP

Automatic VoltageControllers for dry ESPs

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EVAPORATIVE COOLING SYSTEMS

SPRAY IN ACTIONDual-fluid atomization

SPRAY LANCE HEADERSWater and compressed air

distribution to the lances

COOLING TOWERfor cement preheater kiln

SPRAY SYSTEM VALVE RACKFor precise temperature regulation

Spray Cooling Tower Applications

Cooling towers are used to cool and

humidify hot gases in order to improve the

efficiency of the dust collector or to allow theuse of lower priced filter media.

BoldEco implements low maintenance dual

fluid air / water injection systems to drastically

shorten the evaporation time, resulting in dry

bottom operation.

A sophisticated water regulation system

coupled with rapid temperature sensors

provides a quick response to temperature

variations to achieve precise tower outlet gas

temperatures.

Detailed analyses, including model

studies and computer simulations of gasdistribution and tower geometries are

carried out to prevent gas turbulence or poor

gas / water interaction.

HYDRAULIC SPRAY TOWER CONVERSION

Dual-fluid atomization

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LIFTING NEW FABRIC FILTER

Unit was pre-assembled on the ground

and lifted as a unit.

Changeover time, 1 week.

EQUIPMENT CONVERSIONS AND UPGRADES

When existing dedusting systems are

no longer able to achieve the required

exhaust gas emissions, either because

of existing equipment design limitations

or due to increased plant capacity, it isnecessary to consider upgrading or completely

replacing the existing dedusting plant.

BoldEco has carried out several dedusting

plant upgrades and has acquired extensive

know-how in the study and execution of such

projects.

When considering such upgrades or conver-

sions, not only must the ultimate plant ef-

ficiency be taken into account, but also the

time required for conversion and integration

with existing equipment due to short kiln

shutdown requirements.

Upgrade Design and Project Execution

Baghouse Conversion

Reverse gas or shaker to pulse jet

Modifications to gas distributionApplication of various filtering media

ESP Conversion

ESP to pulsejet fabric filter

Conversion to hybrid design

Conditioning Tower Conversion

Redesign of inlet gas distribution section

Replacement of water atomizing lances

Replacement of regulation control system

Exhaust Fan Conversion

Impeller redesign for improved efficiencyImpeller redesign for improved wear

Impeller redesign for higher capacity

BEFORE AND AFTER

ESP TO FABRIC FILTER

CONVERSION

A cement plant ESP converted to

PulseJet Fabric Filter.

Filtering system conversion to fabric filter

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ENGINEERING SERVICES

CFD OF ESP TO BAGHOUSE

CONVERSION

Various runs using Computational Fluid

Dynamics show how difficult it is to

modify the gas flow in an ESP to PJFF

conversion.

CFD Calculations

BoldEco Environment has for acquired

Computational Fluid Dynamics (CFD) tech-

nology, allowing for the simulatation andaccurate study of fluid dynamics problems in

various industrial applications

Typical cases requiring the implemantation

of CFD technology are the optimization

of a poorly functioning GCT, a fabric filter

exhibiting a high number of bag failures or

in preperation of a system upgrade. The

implementation of the results of this technol-

ogy, if tempered by practical experience, can

result in optimizing gas flow distribution, thus

avoiding gas flow related problems like veloc-

ity differentials, recirculation, build-up and

high wear.

In heavilty custom-engineered applications

with the presence of highly abrasive dusts, the

verification of gas flow fields inside the dustcollector itself allows the reduction or elimina-

tion of abrasion and wear on filter bags and

other internal components.

The optimization of the flow distribution is

ESPs is indispensable to achieve the design

efficiencies of the dust collector.

By way of proper study of the fluid dynamics

of an application, it is possible to obtain the

information necessary to correctly engineer

specific equipment.

CFD MODEL OF A SPRAY TOWER

In-house capability

CFD MODEL OF A FABRIC FILTER

A study is carried out on each new

project in order to ensure the proper

performance characteristics

Typical CFD Applications

Typical applications include:

Pressure drop calculations

Gas mixing verification

Build-up and erosion control

Settling chamber and separator efficiency

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GAS AND PARTICULATE SCRUBBERS

EcoMist Technology

Industrial emissions are generally composed

of fine dry particulate and condensed aero-

sols resulting from cooling of the exhaust gas.These fine particles pose a challenge because

they are difficult to capture, greatly affect

stack opacity, and can contain significant

concentrations of toxic compounds.

The EcoMist technology is the result of the

research into higher efficiency scrubbing with

low energy requirements. It is specifically de-

signed to collect sub micron particulate (99.8%).

More than a single technology, the EcoMist

Scrubber is actually comprised of multiple

novel gas cleaning devices, staged in series

and in various combinations to achieve the

required collection efficiency.

The EcoMist Scrubber addresses the deficien-

cies of conventional scrubbers by dealing with

their basic design flaws. The result is a propri-

etary technology that exhibits high collection

efficiency on sub micron particulate and con-

densables, with high turndown capabilities

and excellent energy recovery.

Separate Scrubber Effluents

The EcoMist Scrubber differs from conven-

tional designs in that it segregates the various

stage effluents. In a very practical way, the sys-

tem is designed with separate drains for the

quencher, the sub cooler and the collection

stages, allowing for greatly reduced water

treatment requirements, efficient re-use of ef-

fluents, selective alkali scrubbing, and reduced

toxic effluent processing.

The top photo showsthe emissions of a tra-ditional high energyventuri scrubber. That

same stack (photo be-low) displays no emis-

sions after a EcoMistScrubber upgrade.

EcoMist Scrubber

Typical Efficiencies

Particulate >99.8%

Condensables 99%

Heavy Metals 95-99+%

Acid Gases >99%

AFTER

BEFORE

1

3

5

4

2

Stage 1QUENCHING

Gases are quenched to saturation with

energy efficient atomizers. Eliminates 95

percent of particulate.

Stage 2SUBCOOLING/CONDENSING

(Optional)

Condenses to convert gaseous compo-nents into aerosols.

Stage 3ATOMIZATION

Aerosols and particulate are induced into

negative pressure flow field formed by

the proprietary swirl nozzle.

Stage 4COLLECTION ELEMENT INLET

Gas entrained aerosols and fines move

faster than liquid scrubbing droplets,

causing collision and particle capture.

Stage 5COLLECTION ELEMENT OUTLET

After reaching equilibrium, scrubbing

droplets shoot past aerosols and fines,

causing further collisions and completing

the collection process.

Stage 6SEPARATION

High efficiency separator removes dirty

droplets from the exhaust gases.

EcoMist Scrubber

General Arrangement

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NUISANCE AND MECHANICAL COLLECTION

Multi-Cyclones

Our multi-cyclone is designed for high tem-

perature and abrasive dust applications.

These multi-cyclones are used for high-ef-

ficiency separation of abrasive dusts from

gases, and is especially suited for areas where

pre-separation is desired or where plugging is

a problem.

The design and construction of the

cyclones has been conceived for high tem-

perature applications and fitted with hard-

ened cast parts designed to withstand high

abrasion.

BoldEco supplies various large process exhaust

gas fans. They are designed and manufac-

tured according to the requirements for the

various applications, for dirty as well as clean

applications in power, cement, incineration,

steel, etc. BoldEco can supply fans as large

as 10,000 kW, and factory test fans as large

as 1,000 kW.

KILN/MILL EXHAUST GAS FANGas flow: 828,000 m3/h - 487,000 AcfmInstalled power: 3,000 kW

Nuisance Filtration

In a modern plant, many individual small

and medium sized filters are used for the

dedusting of small production units, conveyor

transfer points and other material handling orstorage equipment.

Our MBC Series fabric filters, solidly designed

and dependable in service, are ready to satisfy

all requirements with regard to reliability, low

maintenance costs and spare part standard-

ization.

The available fans for these filters are built

according to strict engineered standards and

provide high performance in continuous ser-

vice with low maintenance and dependability.

Models are available with integral fans for

ease of installation.Design Variations

The MBC filters are available for different

applications, with differing size bags, hori-

zontal bag arrangements, oval bags, settling

pre-chambers and for high pressure designs.

Please request an MBC fabric filter technical

brochure.

High wear fan impeller

CUSTOM PROCESS FANS

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Skillman, NJ 08558www.boldeco.com

ADVANCED AIR POLLUTION CONTROL SOLUTIONS

Field and Engineering Services

Materials Handling Systems

Gas Cooling and Cleaning Systems

Air and Gas Handling Systems

Silencers and Acoustic Enclosures