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AIR POLLUTION CONTROL SYSTEM UPGRADE ATTUBATSE FERROCHROMERoedolf Koekemoer, Olof Vorster 1 , Frank Fereday 2 , Casper Els 3† , Luthie Els 3 andChris Coetzee 4Tub<strong>at</strong>se Ferrochrome, Steelpoort, South Africa1 W.L. Gore & Associ<strong>at</strong>es, SA, Boksburg, South Africa2 W.L. Gore & Associ<strong>at</strong>es INC, Pittsburgh, United St<strong>at</strong>es3 Consulto Enviro CC, Centurion, South Africa4 Resonant Solutions (Pty) Ltd, Centurion, South AfricaE-mail: roedolf.koekemoer@saman<strong>co</strong>rcr.<strong>co</strong>m; 1 ovorster@wlgore.<strong>co</strong>m; 2 ffereday@wlgore.<strong>co</strong>m;3 <strong>co</strong>nviro@lantic.net; 4 chris@resonant.<strong>co</strong>.<strong>za</strong>ABSTRACTThree electric arc furnaces (EAFs) were <strong>co</strong>nstructed by Union Carbide <strong>at</strong> Tub<strong>at</strong>se Ferrochrome (TFC) in1975. This plant was expanded to four furnaces <strong>at</strong> the East Plant in 1985 and the gas cleaning <strong>system</strong> wasenlarged without taking flow dynamics into <strong>co</strong>nsider<strong>at</strong>ion.In order to improve <strong>co</strong>mpetitiveness, TFC has increased furnace capacity, partially substituted <strong>co</strong>al for<strong>co</strong>ke, and changed the charge mix. These changes increase the he<strong>at</strong> and dust load into the <strong>air</strong> <strong>pollution</strong> <strong><strong>co</strong>ntrol</strong>(APC) <strong>system</strong>. TFC embarked on a project to improve the APC capacity by:• Quantifying the required off-gas capacity• Optimising the aerodynamic flow through the <strong>system</strong> by means of Comput<strong>at</strong>ional Fluid Dynamics (CFD)• Converting the old Brandt Koyo top entry baghouses to bottom entry• Upgrading the cleaning <strong>system</strong>• Installing Gore-tex® ePTFE membrane filter bagsThe estim<strong>at</strong>ion of required off-gas capacity is traditionally done by rule-of-thumb methods such as specificextraction. A more elegant evalu<strong>at</strong>ion method was developed for simul<strong>at</strong>ing the effects of changes in chargemix on the furnace reaction gas volume and the APC <strong>system</strong>. Reaction gases are calcul<strong>at</strong>ed by modelling thereactions taking place in the furnace and off-gas volumes are <strong>co</strong>mpared to both fan and baghouse capacity.This enables identific<strong>at</strong>ion of bottle-necks in the off-gas <strong>system</strong>. CFD techniques were utilized to evalu<strong>at</strong>e geometricimbalances and propose solutions to ensure optimal use of off-gas capacity.The <strong>system</strong> modific<strong>at</strong>ions were <strong>co</strong>mpleted over several months and the modified equipment went into service in May2006.1. INTRODUCTIONTub<strong>at</strong>se Ferrochrome (TFC) was established in 1975 as a joint venture between Gen<strong>co</strong>r and the USA-based<strong>co</strong>mpany Union Carbide. As a result of its close proximity to the chromite mines, a site <strong>at</strong> Steelpoort, approxim<strong>at</strong>ely300 kilometres northeast of Pretoria and Johannesburg, was selected for the <strong>co</strong>nstruction of the plant.The original plant <strong>co</strong>nsisted of three furnaces with an annual capacity of 120,000 tons of high carbonchrome, known in the industry as Charge Chrome. Globally, around 85% of chrome production is used formetallurgical applic<strong>at</strong>ions (primarily the production of stainless steels) with 8% used in chemical applic<strong>at</strong>ionsand 7% in refractory and foundry applic<strong>at</strong>ions.Salient fe<strong>at</strong>ures in the history of TFC are:


436 INFACON XI• 1985: Saman<strong>co</strong>r bought the Union Carbide shareholding in Tub<strong>at</strong>se Ferrochrome.• 1988 to 1990: Expansion of plant capacity to 300,000 tons (5 furnaces).• 1993: Joint venture established with Nippon Denko and addition of 6 th furnace.• 1997: Billiton acquired <strong><strong>co</strong>ntrol</strong>• 2002: Erection of a Pelletising and Sintering plant (520 000 tons per annum) to pelletise and sinter chromitefines. Introducing pellets into the submerged arc furnaces lowers the specific energy <strong>co</strong>nsumptionby improving bed permeability and metallurgical changes achieved through the sintering process.• 2005: TFC sold to the Kermas Group. The Kermas Group is a producer of and trader in ferrochrome andchrome chemicals, with activities in Russia, Germany and Turkey.TFC made the following modific<strong>at</strong>ions to improve furnace ventil<strong>at</strong>ion:• Converting the existing baghouse from top bag gas entry to the more <strong>co</strong>mmon bottom bag entry• Replacing the woven fiberglass bags with ePTFE membrane bags• Significant duct and plenum modific<strong>at</strong>ions based on Comput<strong>at</strong>ional Fluid Dynamic ModellingThe <strong>system</strong> modific<strong>at</strong>ions were <strong>co</strong>mpleted over several months and the modified equipment went into servicein May 2006. The result has been improved furnace evacu<strong>at</strong>ion preventing he<strong>at</strong> and fume from escapinginto the building.The layout of the off-gas handling <strong>system</strong> from Furnaces 1 to 4 is shown below.A brief <strong>system</strong> description after <strong>co</strong>nversion is:• Each of the furnaces extracts to a trombone<strong>co</strong>oler.• 4-off fans are installed after the <strong>co</strong>olers, onefor each furnace.• The fan inlets are interlinked by a headerduct.• A pressure type reverse <strong>air</strong> baghouse filtersoff-gas, with 2-off reverse <strong>air</strong> fans and 32-off<strong>co</strong>mpartments.• After <strong>co</strong>nversion each reverse <strong>air</strong> fan serves16-off <strong>co</strong>mpartments (one each for the Northernand Southern rows of <strong>co</strong>mpartments). Thereverse <strong>air</strong> fans discharge to the risers on thepressure side of the fans (vs current dischargeto the fan inlets).Furnace 1Furnace 2Trombone <strong>co</strong>olerTrombone <strong>co</strong>olerFanR/A fanFanR/A fan2. APC SYSTEM DESIGN REVIEWA design review was done on <strong>upgrade</strong> options forthe East plant (4 furnaces) off-gas <strong>system</strong>. Objectivesof the study included determining the requiredextraction <strong>system</strong> capacity as well as the<strong>system</strong> design and oper<strong>at</strong>ional weaknesses.Furnace 3Furnace 4Trombone <strong>co</strong>olerTrombone <strong>co</strong>olerFanFanBaghouse <strong>co</strong>mpartments2.1 Design Methods Generally UsedFigure 1: APC <strong>system</strong> layoutIn the past, off-gas <strong>system</strong> sizing was done using Specific Extraction (SE) d<strong>at</strong>a, which st<strong>at</strong>es extraction (Nm 3 /h) per furnace energy input (kW), i.e. Nm 3 /h/kW. Specific extraction was benchmarked by visually checkingif a furnace is adequ<strong>at</strong>ely ventil<strong>at</strong>ed and then extrapol<strong>at</strong>ing the SE value to other plants and industries. DesignSE values were for example <strong>co</strong>mpared for various Saman<strong>co</strong>r plants by Wall [1]. Rentz [2] did extensive work


Air Pollution Control System Upgrade <strong>at</strong> Tub<strong>at</strong>se Ferrochrome 437on reducing emissions from Ferroalloy furnaces and i.a. established required SE values for various feed m<strong>at</strong>erialprepar<strong>at</strong>ion regimes.A more sophistic<strong>at</strong>ed method of sizing baghouse equipment is based on furnace he<strong>at</strong> extraction requirements– sometimes referred to as the “X” factor. Ac<strong>co</strong>rding to this method, the he<strong>at</strong> <strong>co</strong>ntent of the submergedarc furnace exhaust gas is directly proportional to the furnace load (influenced by the amount and type of rawm<strong>at</strong>erials and furnace oper<strong>at</strong>ion). The r<strong>at</strong>io of Exhaust Gas He<strong>at</strong> to Furnace Power input yields the “X” factor.Therefore, the rel<strong>at</strong>ionship can be written as follows:Q = X × kW = m × C ×[ T − Th ambWhere Q is the he<strong>at</strong> <strong>co</strong>ntent of the furnace exhaust gas, X is the r<strong>at</strong>io of furnace off gas he<strong>at</strong> to furnace powerinput, m is the mass flow, T h is the hood exhaust gas temper<strong>at</strong>ure and T amb is the ambient temper<strong>at</strong>ure of the<strong>air</strong> drawn into the hood.The X factor is unique for each applic<strong>at</strong>ion and is affected by furnace oper<strong>at</strong>ing <strong>co</strong>nditions and the make upof the charge mix. Factors th<strong>at</strong> can influence the X factor include furnace energy <strong>co</strong>nsumption per alloy ton,fixed carbon in the charge mix, vol<strong>at</strong>ile m<strong>at</strong>ter in the charge mix, w<strong>at</strong>er <strong>co</strong>ntent in the charge mix, reducingagent required per alloy ton and metal re<strong>co</strong>very from the raw ore feed.Typical X values for some <strong>co</strong>mmon ferroalloy processes are 1.3 for Si-Metal, 1.1 for 75% FeSi, 1.0 forSiMn and 0.7 for FeCr.The X factor is normally estim<strong>at</strong>ed from experience, based on field testing and visual observ<strong>at</strong>ions sinceeach applic<strong>at</strong>ion is unique. If he<strong>at</strong> and fume are spilling from the hood during the field testing the furnace he<strong>at</strong>extraction is not adequ<strong>at</strong>e and provisions must be made to increase the furnace draft.2.2 Furnace Reaction Gas Modellingp]In response to problems with above methods in adequ<strong>at</strong>ely estim<strong>at</strong>ing the effect of various process and oper<strong>at</strong>ionalfactors on design of APC <strong>system</strong>s, a more thoroughly process-based method was developed. Furnacereaction gas modelling is done in two steps: furnace reaction gas is estim<strong>at</strong>ed by doing a carbon balance overthe furnace, whereafter the reaction gas is <strong>co</strong>mbusted and diluted with ambient <strong>air</strong>. Varying amounts of dilution<strong>air</strong> are used to calcul<strong>at</strong>e off-gas temper<strong>at</strong>ures <strong>at</strong> the furnace and baghouse inlet.The reaction gas is the gas evolved from the reactions in the b<strong>at</strong>h between ore and reductant as well as vol<strong>at</strong>ilesreleased by the reductant. Details of how the reaction gas is estim<strong>at</strong>ed are given below:• Carbon in the reductant is handled in one of three ways: fixed carbon is assumed to react with ore in theb<strong>at</strong>h, producing carbon monoxide, excess fixed carbon is assumed to be released into the off-gas as purecarbon and is <strong>co</strong>mbusted in the next phase. Part of the carbon <strong>co</strong>ntained in the vol<strong>at</strong>iles is assumed to be<strong>co</strong>mbusted to carbon monoxide by oxygen <strong>co</strong>ntained in the <strong>co</strong>al. The remainder is assumed to <strong>co</strong>me offas carbon for l<strong>at</strong>er <strong>co</strong>mbustion.• Hydrogen in the reductants is assumed to <strong>co</strong>me off as H 2 .• Moisture in the reductants and ore is assumed to report to the gas phase as H 2 O and is not dissoci<strong>at</strong>ed tooxygen and hydrogen.• Wh<strong>at</strong>ever nitrogen there is in the reductants is assumed to report to the gas phase.Carbon, carbon monoxide and hydrogen in the reaction gas (calcul<strong>at</strong>ed above) are <strong>co</strong>mbusted with <strong>air</strong> assumedto be drawn into the furnace hood, providing an off-gas temper<strong>at</strong>ure after <strong>co</strong>mbustion and dilution.He<strong>at</strong> loss <strong>at</strong> the furnace ducting and trombone <strong>co</strong>oler is calcul<strong>at</strong>ed to determine the baghouse inlet gas temper<strong>at</strong>ureand volume flow based on off-gas volumes and temper<strong>at</strong>ures calcul<strong>at</strong>ed with the above carbon massbalance. A standard trombone <strong>co</strong>oler design procedure was used, as proposed in the EPA’s Air Pollution EngineeringManual[3]. The calcul<strong>at</strong>ion model makes use of <strong>co</strong>rrel<strong>at</strong>ions by Sieder and T<strong>at</strong>e[4] for <strong>co</strong>nvection


438 INFACON XIhe<strong>at</strong> transfer on the trombone <strong>co</strong>oler tube inside, McAdams[5] for radi<strong>at</strong>ion he<strong>at</strong> transfer and McAdams[5]for <strong>co</strong>nvection he<strong>at</strong> transfer on the trombone <strong>co</strong>oler tube outside.2.3 Furnace Oper<strong>at</strong>ing Base D<strong>at</strong>aFurnace design power input is 28MW for Furnaces 1 to 3 and 32MW for Furnace 4. Reductants fed to thefurnaces include <strong>co</strong>al, <strong>co</strong>ke and anthracite. The fixed carbon requirement is made up of 60% <strong>co</strong>ke, 20% anthraciteand 20% <strong>co</strong>al. Approxim<strong>at</strong>ely 63% of ferrochrome feed m<strong>at</strong>erial is in the form of pellets, with 32%lumpy ore and 15% <strong>co</strong>ncentr<strong>at</strong>e. Quartz and dolomite are fed as fluxes.2.4 Design criteria and AssumptionsThe criteria used for off-gas <strong>system</strong> design are th<strong>at</strong>, <strong>at</strong> the design off-gas volume, furnace hood temper<strong>at</strong>uremust be below 450°C and baghouse inlet temper<strong>at</strong>ure has to be kept below 240°C. The furnace hood temper<strong>at</strong>urelimit ensures th<strong>at</strong> equipment in the furnace roof is not exposed to high temper<strong>at</strong>ures which result in shortworking life. The criterion is kept rel<strong>at</strong>ively low <strong>at</strong> 450°C, as radi<strong>at</strong>ion he<strong>at</strong> caused by running a furnace withan open b<strong>at</strong>h can boost temper<strong>at</strong>ures significantly. The baghouse inlet temper<strong>at</strong>ure limit ensures th<strong>at</strong> bags arenot exposed to over-temper<strong>at</strong>ure.In reality, one finds th<strong>at</strong> temper<strong>at</strong>ures measured on site differ from modelling calcul<strong>at</strong>ion values in th<strong>at</strong> furnacehood temper<strong>at</strong>ures tend to be a bit higher, caused by radi<strong>at</strong>ion he<strong>at</strong>, while in-leakage of ambient <strong>air</strong> alongthe off-gas <strong>system</strong> causes furnace hood temper<strong>at</strong>ures to be still somewh<strong>at</strong> higher (less gas is actually extractedfrom the furnace) and baghouse inlet temper<strong>at</strong>ure to be lower (further dilution <strong>air</strong> is introduced by in-leakage).2.5 Off-gas Estim<strong>at</strong>ion Results2.5.1 Individual FurnacesThe furnace off-gas <strong>co</strong>nditions <strong>at</strong> furnaces 1 to 3 (28MW) and furnace 4 (32MW) were estim<strong>at</strong>ed for a baghouseinlet temper<strong>at</strong>ure of 220°C. The values are summarised in table 1 below.Table 1: Off-gas estim<strong>at</strong>ion resultsFurnaces 1 to 3 Furnace 4Parameter Unit Value Parameter Unit ValueReaction gas kg/h 7443 Reaction gas kg/h 8090Furnace off-gas temper<strong>at</strong>ure °C 403 Furnace off-gas temper<strong>at</strong>ure °C 379Furnace off-gas volume Am 3 /s 113.5 Furnace off-gas volume Am 3 /s 136Normalised volume Nm 3 /s 42.3 Normalised volume Nm 3 /s 49.9Baghouse inlet temper<strong>at</strong>ure °C 220 Baghouse inlet temper<strong>at</strong>ure °C 220Baghouse volume Am 3 /s 82.8 Baghouse volume Am 3 /s 97.7% CO 2 % (v/v) 3.73 % CO 2 % (v/v) 3.44X-factor 0.80 X-factor 0.77Specific extraction Nm 3 /h/kW 5.44 Specific extraction Nm 3 /h/kW 5.62At furnace 1 to 3, <strong>at</strong> a baghouse normalised flow of 42.3Nm 3 /s, a furnace off-gas temper<strong>at</strong>ure of 403°C anda baghouse inlet temper<strong>at</strong>ure of 220°C is predicted. At furnace 4, <strong>at</strong> a baghouse normalised flow of 49.9Nm 3 /s, a furnace off-gas temper<strong>at</strong>ure of 379°C and a baghouse inlet temper<strong>at</strong>ure of 220°C is predicted.To indic<strong>at</strong>e the effect of varying furnace off-gas volume on off-gas temper<strong>at</strong>ures, the temper<strong>at</strong>ures were calcul<strong>at</strong>edover a range of volumes. Figures 2 and 3 give furnace off-gas and baghouse inlet temper<strong>at</strong>ures forvarying off-gas volumes. The above results form a single point on each of the curves.


Air Pollution Control System Upgrade <strong>at</strong> Tub<strong>at</strong>se Ferrochrome 439The baghouse temper<strong>at</strong>ure line can be seen as the process extraction requirement – i.e. wh<strong>at</strong> baghouse temper<strong>at</strong>uresare produced by the process <strong>at</strong> which extraction volumes. The line does not give any clues as to <strong>at</strong>which temper<strong>at</strong>ure the APC <strong>system</strong> will oper<strong>at</strong>e. To obtain the oper<strong>at</strong>ing point, the fan(s) and baghouse capacitieshave to be <strong>co</strong>mpared with the process extraction requirement. On the graph, two further curves areplotted: fan and baghouse normalised extraction capacity as a function of temper<strong>at</strong>ure. The fan capacity curveis estim<strong>at</strong>ed by using the design fan curve and taking into ac<strong>co</strong>unt the effect of gas density on fan performance.Fan laws are used to adjust the fan performance ac<strong>co</strong>rdingly. The baghouse capacity curve is estim<strong>at</strong>edby taking the design actual filter volume and <strong>at</strong> each temper<strong>at</strong>ure calcul<strong>at</strong>ing the <strong>co</strong>rresponding normalisedvolume for a <strong>co</strong>nstant actual inlet volume (i.e. to ensure th<strong>at</strong> the actual baghouse volume remains <strong>co</strong>nstant).1000950Temper<strong>at</strong>ure, °C90085080075070065060055050045040035030025020015010050BaghousecapacityFan capacityBaghousetemper<strong>at</strong>ureFurnace hood temper<strong>at</strong>ure220°C lineOper<strong>at</strong>ingpoint010 15 20 25 30 35 40 45 50 55 60Volume, Nm 3 /sFigure 2: Extraction volume vs Temper<strong>at</strong>ure – Furnaces 1, 2 or 31000950Temper<strong>at</strong>ure, °C900Furnace hood temper<strong>at</strong>ure850800 Baghousecapacity750700650600 Fan capacity550500450Baghouse400temper<strong>at</strong>ure350300250220°C line200150Oper<strong>at</strong>ing100point50010 15 20 25 30 35 40 45 50 55 60Volume, Nm 3 /sFigure 3: Extraction volume vs Temper<strong>at</strong>ure – Furnaces 4


440 INFACON XIThe range of temper<strong>at</strong>ures for varying off-gas volumes can be appreci<strong>at</strong>ed from the graphs, as can the importanceof maintaining the off-gas <strong>system</strong> in good <strong>co</strong>ndition: decreasing volumes result in rapidly increasingfurnace hood temper<strong>at</strong>ures as well as baghouse inlet temper<strong>at</strong>ures.In order to <strong>co</strong>mpare process requirement with fan and baghouse capacities, the baghouse and fan capacityare viewed vs the baghouse temper<strong>at</strong>ure curve. If the baghouse and fan capacity curves are above the baghousetemper<strong>at</strong>ure curve, then the off-gas <strong>system</strong> (fan and baghouse) have sufficient capacity to adequ<strong>at</strong>elyventil<strong>at</strong>e the <strong>system</strong>. The first point of intersection of the fan or baghouse capacity curve with the baghousetemper<strong>at</strong>ure curve shows the maximum off-gas oper<strong>at</strong>ing capacity. If the above point of intersection is <strong>at</strong> anormalised volume where both the baghouse temper<strong>at</strong>ure and the furnace temper<strong>at</strong>ure are within design criteria,then the off-gas <strong>system</strong> is adequ<strong>at</strong>ely sized for the applic<strong>at</strong>ion.For furnaces 1 to 3, the point of intersection of the baghouse capacity curve with the baghouse temper<strong>at</strong>urecurve is <strong>at</strong> 45Nm 3 /s. At this volume, the furnace temper<strong>at</strong>ure is below 400°C and the baghouse temper<strong>at</strong>urebelow 220°C. The <strong>co</strong>nclusion from the curve is therefore th<strong>at</strong> the off-gas <strong>system</strong> has sufficient capacity forthe applic<strong>at</strong>ion.For furnace 4, the baghouse capacity curve is the first to intersect with the baghouse temper<strong>at</strong>ure curve –i.e. the baghouse capacity is limiting. The point of intersection is <strong>at</strong> a baghouse temper<strong>at</strong>ure of 233°C, whichis above the oper<strong>at</strong>ing guideline of 220°C. The fan capacity intersects the baghouse temper<strong>at</strong>ure curve <strong>at</strong>223°C, which is marginally above the oper<strong>at</strong>ing guideline. The <strong>co</strong>nclusion drawn from the curve is th<strong>at</strong> thebaghouse capacity is limiting and the <strong>system</strong> will not be able to oper<strong>at</strong>e <strong>at</strong> 220°C.However, furnace 4 does not oper<strong>at</strong>e in isol<strong>at</strong>ion and the <strong>co</strong>mbined effect of all 4 furnaces on the fans andthe baghouse was viewed.2.5.2 Combined APC System ModellingThe graph below <strong>co</strong>mbines the process impact of the four furnaces and the capacities of the 4-off fans and 32-off baghouse <strong>co</strong>mpartments. Curves shown are <strong>co</strong>mbined average furnace temper<strong>at</strong>ure (all 4 furnaces), <strong>co</strong>m-1000950900Temper<strong>at</strong>ure, °C85080075070065060055050045040035030025020015010050BaghousecapacityBaghousetemper<strong>at</strong>ureFan capacity220°C lineFurnace hood temper<strong>at</strong>ureOper<strong>at</strong>ingpointOper<strong>at</strong>ing range050 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200Volume, Nm 3 /sFigure 4: Combined Furnaces Extraction volume vs Temper<strong>at</strong>ure


Air Pollution Control System Upgrade <strong>at</strong> Tub<strong>at</strong>se Ferrochrome 441bined average baghouse temper<strong>at</strong>ure (total baghouse), baghouse capacity curve for all 32 <strong>co</strong>mpartments and<strong>co</strong>mbined fan capacity curve for all 4 fans. To indic<strong>at</strong>e the impact of <strong>system</strong> in-leakage, a 5% <strong>air</strong> in-leak wasassumed close to the fans.The <strong>co</strong>mbined graph indic<strong>at</strong>es the following:• At a total extraction volume of 170Nm 3 /s, a baghouse inlet temper<strong>at</strong>ure of 220°C is achieved.• The furnace stack temper<strong>at</strong>ure can be maintained <strong>at</strong> 420°C <strong>at</strong> this extraction volume.• The fan and baghouse capacity is sufficient to oper<strong>at</strong>e <strong>at</strong> 170Nm 3 /s <strong>at</strong> a temper<strong>at</strong>ure of 220°C.• The specific extraction required is 5.5Nm 3 /h / kW with an X-factor of 0.79.• Installed baghouse and fan design capacities (after baghouse <strong>co</strong>nversion) are sufficient to achieve therequired extraction volume.The effect of in-leakage on the <strong>system</strong> was to establish an oper<strong>at</strong>ing range: without in-leakage a volume of177Nm 3 /s is required to main a baghouse inlet temper<strong>at</strong>ure of 220°C. The neg<strong>at</strong>ive effect of in-leakage is th<strong>at</strong>furnace off-gas temper<strong>at</strong>ures rise with increasing in-leakage down the line. The average furnace off-gas temper<strong>at</strong>ureincreased from 400°C <strong>at</strong> 177 Nm 3 /s to 420°C <strong>at</strong> 170 Nm 3 /s.3 AERODYNAMIC OPTIMISATION AND BAGHOUSE CONVERSIONIn the not so distant past <strong>co</strong>mput<strong>at</strong>ional fluid dynamics (CFD) was restricted to very powerful <strong>co</strong>mputers andhighly specialized users. The quantum leap in <strong>co</strong>mputer processing power has made CFD analysis accessibleto the engineering industry in general as opposed to the NASAs of the world.TFC is one of the enlightened <strong>co</strong>mpanies th<strong>at</strong> used this quantum leap in technology to their benefit to optimizethe aerodynamic flow through their gas cleaning <strong>system</strong>. A number of proposed ducting layout modific<strong>at</strong>ionswere simul<strong>at</strong>ed in EFD.Lab 6.0 to find an optimized/balanced resistance through the <strong>system</strong>. An optimized<strong>system</strong> will result in an increase in production capacity and a balanced <strong>system</strong> will ensure uniform wearthrough the <strong>system</strong> and ultim<strong>at</strong>ely longer oper<strong>at</strong>ional life. With the addition of furnace 4 in the 1980s flowdynamics was not taken into <strong>co</strong>nsider<strong>at</strong>ion as can be seen from the increased pressure drop through furnaceFigure 5: Baghouse inlet duct <strong>co</strong>nfigur<strong>at</strong>ion: before


442 INFACON XI4 in Table 1. The difference in pressure drop was due to the addition of bends not present in furnaces 1-3. Theproposed optimized layout <strong>co</strong>nsisted of four new ducts th<strong>at</strong> will result in flow symmetry as indic<strong>at</strong>ed by thepressure drop in Table 1. The unbalance in the <strong>system</strong> was therefore reduced from 417Pa to less than 21Pa.Due to the fact th<strong>at</strong> numerous simul<strong>at</strong>ions can be performed in a rel<strong>at</strong>ively short time, the design can be optimizedbefore <strong>co</strong>nstruction starts. CFD makes up only a fraction of the total project <strong>co</strong>st, yet it <strong>co</strong>uld resultin significant improvement of profits due to higher efficiency and lower maintenance <strong>co</strong>sts to the <strong>system</strong>.Figure 6: Baghouse inlet duct <strong>co</strong>nfigur<strong>at</strong>ion: afterTable 2: Ducting pressure drop before and after modific<strong>at</strong>ionLoc<strong>at</strong>ion Pressure Drop Before (Pa) Pressure Drop After (Pa)Furnace 1 553 452Furnace 2 561 469Furnace 3 451 455Furnace 4 868 449With the new bottom entry <strong>co</strong>nversion the gas was directed into the hopper and through the bags as opposedto through the bags and into the hopper with the original design. A CFD simul<strong>at</strong>ion was done to ensure uniformflow into the hopper and ultim<strong>at</strong>ely entering the bags. This avoids velocity abrasion of the filter bagsand re-entrainment of dust from the hopper. The following two pictures illustr<strong>at</strong>e the velocity profile throughthe new ducting as well as the hopper before entering the bags.4. CLEANING SYSTEM UPGRADEThere are many factors th<strong>at</strong> affect the performance of a baghouse, especially the filter bags. Earlier experiencehas shown the following variables affect the pressure drop across the filter bags.• Dust gener<strong>at</strong>ion r<strong>at</strong>e• Humidity of the gas• Electrost<strong>at</strong>ic <strong>at</strong>traction between the bag and the dust• Bulk density of the dust• Dust particle size


Air Pollution Control System Upgrade <strong>at</strong> Tub<strong>at</strong>se Ferrochrome 443Figure 7: Flow distribution through hopperFigure 8: New bottom entry <strong>co</strong>nversion• Chemical <strong>co</strong>mposition of the dust• Filter velocity (the <strong>air</strong> to cloth r<strong>at</strong>io)• Effectiveness of the cleaning <strong>system</strong>While most of these factors are beyond the <strong><strong>co</strong>ntrol</strong> of the baghouse oper<strong>at</strong>or the effectiveness of the cleaning<strong>system</strong> can be improved by <strong>co</strong>mputerized <strong><strong>co</strong>ntrol</strong> of the cleaning cycle. This <strong>co</strong>mputerized technique is nowoften referred to as “smart cleaning”.There is direct rel<strong>at</strong>ionship between gas flow through the bags and the pressure drop across the bags duringreverse <strong>air</strong> cleaning. This is true up to a threshold point where the additional reverse <strong>air</strong> pressure does no moregood and needlessly increases the baghouse pressure drop since the reverse <strong>air</strong> must re-filtered by the on line<strong>co</strong>mpartments.Since each <strong>co</strong>mpartment is a different distance from the reverse <strong>air</strong> fan inlet and some <strong>co</strong>mpartments capturemore dust due to the inherent flow imbalance within the baghouse it is best to vary the reverse <strong>air</strong> volume tomaintain a <strong>co</strong>nsistent pressure drop across the bags during cleaning. The most practical approach in most casesis to use a variable speed drive (VSD) on the reverse <strong>air</strong> fan motor based on the output of a pressure <strong><strong>co</strong>ntrol</strong>loop. This requires each <strong>co</strong>mpartment to be fitted with a pressure transmitter to measure the tubesheet pressuredrop and for those signals to be logged by the baghouse programmable <strong><strong>co</strong>ntrol</strong>ler (PLC).If the pressure set point is not achieved the PLC signals the VSD to increase or decrease the motor speedthe next time th<strong>at</strong> particular <strong>co</strong>mpartment <strong>co</strong>mes up for cleaning. Attempts to readjust the reverse <strong>air</strong> fan motorspeed while the reverse <strong>air</strong> damper is open have not been successful.5. FILTER BAG REPLACEMENTTub<strong>at</strong>se previously utilized woven fiberglass filter bags. Fiberglass m<strong>at</strong>erial is known to have many advantages[7]:• Non <strong>co</strong>mbustible because it is <strong>co</strong>mpletely inorganic• Zero moisture absorption; therefore, it is not subject to hydrolysis• Dimensional stability (low <strong>co</strong>efficient of linear expansion)• Very high strength but poor resistance to flex and abrasion; however, there are chemical surface tre<strong>at</strong>mentsth<strong>at</strong> improve the flex and abrasion characteristics of fiberglass• Woven fiberglass can oper<strong>at</strong>e <strong>co</strong>ntinuously up to 260°C and depending on the surface tre<strong>at</strong>ment withstandup to 288°C for short periods.


444 INFACON XIPerson [8] has explained the rel<strong>at</strong>ively high filter drag of <strong>co</strong>nventional woven fiberglass m<strong>at</strong>erial when appliedto metallurgical fume. Additionally, one <strong>co</strong>uld reasonably expect higher particul<strong>at</strong>e emissions throughthe <strong>co</strong>nventional fiberglass filter media since the filter cake must be sacrificed to maintain <strong>air</strong>flow. Whilearamid m<strong>at</strong>erial (good to 204°C) in shaker cleaning applic<strong>at</strong>ions shows lower filter drag than woven fiberglassm<strong>at</strong>erial, there is limited experience with aramid in EAF baghouses. Furthermore, in the limited caseswhere aramid had been used in EAF applic<strong>at</strong>ions, the results have not been en<strong>co</strong>uraging.Eriksen [9] and Stordahl [10] reported th<strong>at</strong> GORE-TEX ® membrane/fiberglass filter media has substantiallylower filter drag than <strong>co</strong>nventional media in metallurgical fume applic<strong>at</strong>ions. Previous work by Hall, et al [11]demonstr<strong>at</strong>ed the improved filtr<strong>at</strong>ion efficiency of GORE-TEX ® membrane filter bags in a steel EAF applic<strong>at</strong>ion<strong>at</strong> British Steel when <strong>co</strong>mpared to the results with various woven synthetic filter media <strong>at</strong> the sameinstall<strong>at</strong>ion.Difference Between Conventional and Membrane Fabric Filtr<strong>at</strong>ion TechnologiesWhen fabric filter dust <strong>co</strong>llectors became a viable technology years ago, the available fabric filter media includedwool and <strong>co</strong>ttons, then progressed to polyester, aramid, fiberglass, etc. This method of filtr<strong>at</strong>ion wasand is referred to as <strong>co</strong>nventional depth filtr<strong>at</strong>ion. W. L. Gore & Associ<strong>at</strong>es, Inc. (Gore) introduced expandedpolytetrafluoroethylene (ePTFE) membrane surface filtr<strong>at</strong>ion, offering significant advantages over <strong>co</strong>nventionaldepth filtr<strong>at</strong>ion. The <strong>co</strong>mparison of these two filtr<strong>at</strong>ion methods has been explained a number of timesin the liter<strong>at</strong>ure including the paper by Yerkes [6] <strong>co</strong>mparing the performance of polyester and GORE-TEX ®filter bags <strong>at</strong> Corus Tuscaloosa Steel.200X 600X 200X 600XFigure 9: Scanning Electron Microphotograph: Fiberglass Fabric vs ePTFE MembraneThe lower filter drag typical of GORE-TEX ® membrane filters reduces the <strong>system</strong> resistance and allowsincreased gas flow through the baghouse. With proper inspection and maintenance, GORE-TEX ® membrane/acid resistant fiberglass fabric filter bags oper<strong>at</strong>e effectively for many years. In most cases, even after fiveyears, the GORE-TEX ® membrane filter bags do not show a drop in gas flow capability or filtering efficiency.Elverd, et al [6] documented the improved furnace evacu<strong>at</strong>ion, longer bag life, lower maintenance <strong>co</strong>st, anddecreased particul<strong>at</strong>e emissions <strong>at</strong> Tennessee Alloys Corpor<strong>at</strong>ion after the install<strong>at</strong>ion of GORE-TEX ® expandedPTFE (ePTFE) membrane/fiberglass filter bags in 1993. Substantially all of those filter bags werestill in service after eight years.W<strong>at</strong>er leaks are a <strong>co</strong>mmon problem in EAF fume tre<strong>at</strong>ment <strong>system</strong>s. These w<strong>at</strong>er leaks, if carried over tothe baghouse, will blind <strong>co</strong>nventional filter media in a short time period. Since the <strong>air</strong>flow through <strong>co</strong>nventionalmedia does not re<strong>co</strong>ver after an extended w<strong>at</strong>er leak, new bags are required. Due to the hydrophobic


Air Pollution Control System Upgrade <strong>at</strong> Tub<strong>at</strong>se Ferrochrome 445n<strong>at</strong>ure of the membrane, GORE-TEX ® membrane filter bags have proven their ability to re<strong>co</strong>ver from w<strong>at</strong>erleaks.GORE-TEX ® expanded PTFE (ePTFE) membrane/fiberglass filter bags offered TFC a <strong>co</strong>st-effective wayto deal with the demands of increased furnace productivity, leading to a higher required furnace extractionvolume to the <strong>system</strong>.6. CONCLUSIONSAt the time of writing (July 2006), Tub<strong>at</strong>se had restarted only the No 2 and No 4 furnaces. It was thus difficultto assess the whole <strong>system</strong> effectiveness. Initial indic<strong>at</strong>ions are, however, positive:• Emissions from the baghouse have been significantly reduced.• Pressure drops across the filter bags are as predicted during design.• Inlet temper<strong>at</strong>ures are lower, but this is due to in leakage of ambient <strong>air</strong> from the furnaces th<strong>at</strong> are stillidle.This paper makes a <strong>co</strong>ntribution by presenting Furnace Reaction Gas Modelling as an altern<strong>at</strong>ive to previouslyused design methods.DEDICATIONThis paper is dedic<strong>at</strong>ed to the memory of Casper Els who died on the 7 th of November 2006 after the initialpaper was submitted. His invaluable <strong>co</strong>ntribution to the field of <strong>air</strong> <strong>pollution</strong> <strong><strong>co</strong>ntrol</strong> is hereby acknowledged.REFERENCES[1] Wall, CD, “Interim report on dust plant r<strong>at</strong>ing Tub<strong>at</strong>se Furnaces 1 to 4”, 1998.[2] Rentz, O, “Emissionsverminderung bei Ferrlegierungen”, Karlsruhe, 1971.[3] US EPA, “Air Pollution Engineering Manual”, 2 nd Edition, Research Triangle Park, N.C., 1973.[4] Sieder, E.N. and T<strong>at</strong>e, G.E., “He<strong>at</strong> transfer and pressure drop of liquids in tubes”, Ind. Eng. Chem., 1936.[5] McAdams, W.H., “He<strong>at</strong> Transmission”, 2 nd Edition, McGraw-Hill Book Co Inc, New York, 1942.[6] Yerkes, J. E., Renfroe, J. T., Hosmer, W. M., Fereday, F., Kleine – Moellhoff, P., Sanders, S. M., “Benefits of HighTemper<strong>at</strong>ure Membrane Filter Media in the Tuscaloosa Baghouse”, Sixth European Electric Steelmaking Conference,1999.[7] McKenna, J. D. and Turner, J. H., Fabric Filter – Baghouses I Theory, Design, Selection, Valley Printers, ETS Inc.1998.[8] Person, R.A. “Current St<strong>at</strong>us of Ferroalloy Emission Controls”, Electric Furnace Conference Proceeding, Volume33, 1975.[9] Eriksen, E., “E<strong>co</strong>nomy and Development in Ferroalloy Dust Collection”, Electric Conference Proceedings, Volume43, 1985.[10] Stordahl, S., “Recent Developments in Elkem Pollution Control Technology”, The User and Fabric Filter EquipmentIV Proceedings, 1988, Toronto, Canada.[11] Hall, G.D., Pr<strong>at</strong>er, B.E., Taylor D.,Topham T.,”A Study of Electric Steelplant Baghouse Filtr<strong>at</strong>ion”, British SteelCorpor<strong>at</strong>ion, Swinden Labor<strong>at</strong>ories, Rotherham, S<strong>co</strong>tland, U.K., May 1991.

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