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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
Recommended