Dustex Overview for DustexTurkey Training

8/12/2019 Dustex Overview for DustexTurkey Training

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Corporate History

Dustex Corporation Dustex was founded in 1947 as a division of American

Precision Industries

Dustex initially entered into the market providingspecialty cyclones for food and chemical processing

Dustex holds 18 APC equipment patents


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Corporate Overview

Dustex Corporation Dustex is incorporated in North Carolina

Privately-held company with ownership active inmanagement and project execution

Dustex maintains three office locations Corporate headquarters located in Kennesaw, Georgia

Automation/Controls/Aftermarket Division located in Acworth,Georgia

Fabrication Division located in Rocky Mount, NC

Captive Fabrication Shop in Kingston, OH


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Dustex Product Lines

Pulse Jet and Reverse air baghouses

Dustex enhanced design pulsejet baghouse withLong Bag technology

Mercury control systems / Activated carbon

injection Sodium Bicarbonate, Trona and Hydrated lime

injection systems Multi-pollutant High Rate Recirculation fluid bed

scrubber systems Multi-clones

Standard products Bin vents

Dust valves

Material handling collectors


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Primary Markets Served

Utility boilers

Industrial / institutional boilers

Biomass and Waste to Energy

Cement and Lime Plants Steel (primary and secondary)

Foundry

Food Processing

Chemical Processing

Aluminum


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Dustex In-House Capabilities

Engineering including Computational Fluid Dynamics

modeling

Fabrication

Design/Build Project Management

Controls and Automation

Commissioning and Aftermarket Support


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Dustex CFD Modeling

Dustex provides 3D flow modeling on critical areas to thescrubber, baghouse and ACI Injection systems

3D solid modeling and flow analysis is performed in-house

Provides improved flow profiles in modules

Improved Cleaning Performance

Reduced potential for bag abrasion


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Dustex Fabric Filters


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Purpose of the Baghouse

The function of thebaghouse is to collect theparticulate waste fromProcess Gas Streams witha high level of efficiency

The baghouse alsoprovides enhancedmercury control withactivated carbon injectionprior to baghouse.

Baghouse aids in HCl and

SO2/SO3 control whencoupled with a dryscrubber


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Baghouse advantages over ESP

Capable of handling large temperature and volume swings.

Higher level of mercury control with lower Carbon

consumption on PAC systems.

Capable of much lower emissions levels.

Does not require pretreatment of gasses to control

particulate.

Generally speaking, baghouses have an overall lower total

lifetime maintenance cost as compared to ESPs. ESPshave a reported high operational upkeep.


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Fabric Filter Design Types


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Reverse Air Filters


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Reverse Air Design

Developed for with large

volumes and large bags

Air flows up through the

inside of the bags wheredust collects

Cleaning is by a reverse

air fan that pushes air

backwards through the

filter

Limited to 2.25:1 gross

A/C


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Reverse Air Design

Designed as a panelized unit

MUST clean offline

Can be Cost effective at volumes Over 1,000,000

acfm (1,700,000 m3/hr) Formerly used in Utility industry, but largely

replaced by pulse jet

Still seen rarely in the Steel industry


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Pulse Jet Baghouse

Inlet Design Comparison

Hopper Entry vs.

Housing Inlet Design, Cross-flow


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Traditional Hopper Entry Design

Developed for use with

short bags (< 18 feet)

Air flow up through bags

inhibits cleaning and leadsto re-entrainment

Can lead to abrasion

problems and high

pressure drop

Used by some suppliers

for long bag designs

Limited to 4:1 A/C


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Typical Hopper Entry Collector


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Traditional

Hopper Entry Ladder Baffle


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Hopper Entry Advantages

The original Pulse Jet filter design

Cost effective at volumes less than 300,000 acfm(500,000 m3/hr)

Commonly supplied with walk in plenum Best design for low volumes where price is the

most critical factor


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New Technology

Housing Inlet Design, Cross-flow


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Side Plenum Design

Single Modules with up to 304 bags

Side Plenum ships loose

Cost effective at volumes up to 500,000 acfm

(850,000 m3/hr) Shop installed Hopper heaters and Insulation with

cladding


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Side Housing Inlet

New technology for longbag design >24 (7.3m)

Flow enters side of moduleand flows across bags

Efficient on-line cleaning athigh A/C ratios

Reduces bag abrasionissues


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Side Plenum Module


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Split Module Design

Single Modules with up to 576 bags

Module ships as two halves with hoppers attached

Cost effective at volumes in excess of 400,000

ACFM (680,000m3/hr) Single Train units up to 2,000,000 ACFM

(3,400,000 m3/hr)

Shop installed insulation and cladding

Can be adapted to panelized design if required forlarge volume


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Split Module Erection


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Design Features


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Dustex Top Door

Monolithic top door withintegrated CleaningSystem allows for easybag access while avoiding

confined space concerns Floating Pan design

provides allows for moduleexpansion without leaking

Intermediate pressurepulse system providesefficient cleaning and longbag life.


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Integral Top DoorBottom View

Showing blow pipes


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Header and Pulse Valve Assy.


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Clean air plenum


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Top of Tube Sheet


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Bag Cleaning

On line vs. Off line


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On-lineCleaning Operation

Dirty Flue gas

from upstream

Flue stream to

ID Fans

DP


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On-lineCleaning Operation

Dirty Flue gas

from upstream

Flue stream to

ID Fans

DP

High DP condition detected


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On-line Cleaning Operation

Dirty Flue gas

from upstream

Flue stream to

ID Fans

Cleans a row of filters

DP

Solenoid valve opens

While one row is being cleaned, the other rows in

the module continue to operate


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On-line Cleaning Operation

Dirty Flue gas

from upstream

Flue stream to

ID Fans

DP

Solenoid valve closes

System starts another

row of bags


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37

Off-lineCleaning Operation

Dirty Flue gas

from upstream

Flue stream to

ID Fans

DP


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Off-line Cleaning Operation

Dirty Flue

gas from

upstream

Flue stream to

ID Fans

DP

High DP condition detected


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Off-line Cleaning Operation

Dirty Flue

gas from

upstream

Flue stream to

ID Fans

Stop flow in

Module

DP


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Off-lineCleaning Operation

Dirty Flue gas

from upstream

Flue stream to

ID Fans

Clean a row of filters

DP

Solenoid valve opens


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Modern developments in Pulse

Jet Baghouse Technology

CFD Modeling use as a progressive tool fordistribution and inlet development

Cross-Flow Inlet Design contrasted with older hopperentry Cross flow development has allowed for:

more effective cleaning systems

Significant reduction in high velocity streamlining andabrasion

Elimination of can velocity

Increase in Air to Cloth ratios (cloth face velocity) due tomedia effectiveness

Increased filter life

Aid in filter bag length increase


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Additional Modern developments Increase in filter bag length (as long as 10 meters) due to advancements an

testing of cleaning systems in conjunction with cross flow technology Development of long bag technology has allowed a very cost effective option to

reverse air collector with smaller footprint

Modern Long bag technology has allowed pulse collectors with the footprintequal to or smaller than Electrostatic Precipitators, with the added benefit of noemission swings with load swings

Module lift-off door sealing advancements reducing or eliminating air

infiltration which causes corrosion and eliminates confined space issuesthat would be present n a walk-in plenum unit

Filter media developments allowing wider range of applications andefficiency

Control system advancements allowing: Cost effective PLC based cleaning controls (without timer cards)

Cost effective and reliable demand based cleaning which allows for tightbaghouse DP control eliminating Furnace draft swings and helping retainsorbents on the filter media for maximizing HAP reduction particularly forMercury control and dry scrubbing applications

Easier plant wide networking and integration with DCS equipment as well asremote diagnostics options.

PLC based redundancy availability


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Dustex Fabrication

Dustex Fabrication Shop in NCCaptive Shop in OH


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Modularized Utility collector inDustex Fab shop


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Module Half On Jig


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Erection Friendly Designs

Side Plenum and Split Module for

More cost effective field erection


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Side Plenum Erection

E ti Ti li (1 f 3)


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Typical Baghouse Module First Baghouse Module Being Lifted Into Place

First Baghouse Module Being Set In Place First Six (6) Baghouse Modules Set In Place

Erection Timeline (1 of 3)

Erection Timeline (2 f 3)


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Final Six (6) Baghouse Modules Set In Place Baghouse Inlet-Outlet Duct

Baghouse Top Section w/Installed Air Pipe Baghouse Penthouse Steel

Erection Timeline (2 of 3)

E ti Ti li


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Baghouse Penthouse Structural Steel Erection Baghouse Penthouse Structural Steel Erection

Baghouse Penthouse Level (Top of Baghouse El.287-0)

Erection Timeline(3 of 3)


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Baghouse Dynegy Unit 2


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Completed 110MW unit


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Completed 300MW Unit


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Nova Scotia Power


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Activated Carbon Injection

Systems (ACI)


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ApplicableIndustries

Solid Fuel Boilers / Power Generation

Minerals Processing / Cement Plants Municipal Solid Waste Combustion


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Purpose of ACI

Introduce activated carboninto the flue stream toadsorb Mercury andMercury compounds

present in the flue gasses Activated Carbon Can Also

be used for Dioxin/Furancontrol in MSWapplications

Carbon is injected throughan array of injection lancesto insure even distribution


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Dustex ACI Scope

Dual Discharge Silo

Pre-assembled Loss-in-

Weight feed system

Injection lance supplyincluding CFD model

Standalone Control and

Power Panel

Skid Mounted


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ACI systems


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ACI Silo


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Mercury Removal Test Data

1,058,000 ACFM operating at 375 deg F has

tested at 90% mercury reduction with 0.58

#/million ACF injection rate

410,000 ACFM operating at 325 deg F has testedat 90% mercury reduction with 0.75 #/million ACF

injection rate


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Scrubbers for Removal of SOx

and Acid Gases

Three Main Methods of Utility Size Scrubbers


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Three Main Methods of Utility Size Scrubbers

Spray Dryer

Advantages:

Relatively Low Capital cost

Easy for Retrofit applications with existing baghouse

Simplicity

Disadvantages:

Not good for higher than 90% removal efficiencies

Not good for Fuel Flexibility

Lime slurry Equipment present

Very High Maintenance

Three Main Methods of Utility size Scrubbers


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Lime Slurry reagent based Wet Scrubber

Advantages: High Removal efficiency, greater than 90%

Fuel flexibility

Not size limited

Disadvantages: Slurry Based

High horsepower consumption

More equipment hence associated maintenance

Three Main Methods of Utility size Scrubbers


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Circulating dry scrubber

Advantages:

Low Maintenance

Simplicity

High Removal efficiencies, greater than 90%

Relatively Low Capital cost

Fuel Flexibility Scrubbing efficiency higher than spray dryer, Well over

90% removal

Lower operating temperatures with high reagentconcentration allows adsorbsion of Heavy metals

Disadvantages:

Equipment elevation

Requires Multiple trains for units over 300 MW

Dustex High Circulation Rate


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Dustex High Circulation Rate

Dry Fluid Bed Scrubbers HCl, SO2, HF Control

Scrubbing efficiencies >90%

Lower reagent consumption due to recirculation

Lower Maintenance than Spray Dryer or Wet Scrubber Low operating temperature gives side benefit of Heavy

Metals Control

Utility projects over 50 MW executed in conjunction with

Babcock Power


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Operating Principal

Flue Gas Enters bottom of scrubber tower

Fresh Reagent and recirculation from the fabric filter are

added to create desired tower pressure drop

Water Spray cools to 20-30 F above saturation

Carry over material is collected in the fabric filter

baghouse.


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Scrubber Installation

110 MW Installation


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110 MW Installation

Documents

Dustex Overview for DustexTurkey Training