environmental pollution control heat recovery technology · −simultaneous absorption, particulate...
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Fluidized Bed Technology:
− Scrubbers, Absorbers & Strippers
History:
− Developed & progressed by FTL & Osprey since 1991
− Nearly 500 scrubber and stripper plants installed
worldwide, extensively in Europe & N. America.
− 10 installations in Australia
− Blue Chip Clientele: BHP Billiton, Visy, Kronos etc.
GAS
LIQUID
3-Phase Turbulent
Flow
Ellipsoid Shape Skewers The C.O.G
Tumbling / Rotation Of Packing
Fluidized Bed Technology:
− Traditional Packed Towers & Sieve
Plates limited by their Available
Surface Area for Mass Transfer.
− Packed Towers Blockage from
solids or dust particles
increases in DP & diminished
efficiency.
− TURBOIDS/TURBOPAK® fluidised
by the ascending gas stream
− Highly turbulent mixing & liquid
shearing
REVOLUTIONARY PACKING
− Patented FTL/Osprey Turboid® & Turbopak ®
− Traditional Sphere Shaped Packing Proved Unstable
(Swirl Effect / Sideways Movement)
− Other Issues Included Channelling Of Gas, Poor
Distribution of The Bed & Unreliable Performance
− Patented Ellipsoidal & Ovoidal Shapes Overcame
These Issues
− More Energy Efficient To Fluidize
− Indent Adds Extra Thrust To The Tumbling Motion
− Skewed C.O.G of the media causes them to oscillate
TurboPak® Ovoid with Concave
Indentation
Tumbling & Intense Violent Mixing
Gas Flow
Unsurpassed Mass & Heat Transfer
− Turbulence creates very high Reynold’s Number High Mass &
Heat Transfer Coefficients
− Intimate “Mixing” Provides Fast Contact-Driven Mass Transfer /
Absorption
Equipment Size Reduction
− Reduced Equipment Height/Footprint compared to equivalent
packed/sieve-plate tower
Guaranteed Blockage-Free Operation
− Bed remains 100% blockage-free even using slurries, biomass &
precipitating systems
− Flooding is Impossible - L/G Range = 0.1 L/m3 - No Upper Limit
Multi-use Functionality
− Simultaneous Absorption, Particulate Removal & Heat Recovery in One
− More Energy Efficient Than a Venturi / Packed Tower Combination for
the Same Performance
Operating Characteristics: Mass & Heat Transfer Rates
− Overall Gas Mass Transfer Coefficient (of Species A), KOG,A Is A Function Of Many Things,
One Of Which Is The Pressure Gradient dP/dh
− The Pressure Gradient Is A Function Of L/G, y (Shape Factor), f (Accentric Factor), S
(Shape Factor), r (Gas Density).
− Using Ellipsoidal Packing Effects Both y and f (=1.0 For Spheres)
− Varying The Size And Shape Of The Element One Can Control The System dP/dh & \
Regulate The Mass, Heat Or Particulate Transfer Efficiency
− Another Key Factor Is The “Surface Renewal Rate” - The Rate At Which Fluid Elements At
The Phase Interface Are Being Replace By Fresh Elements From The Bulk
− Simply By Increasing Pressure Gradient Will Not Produce Optimum Design Conditions…
− The Absolute Value Of The Mass & Heat Transfer Coefficients Is In Reality A Function Of Bed
Turbulence, Surface Renewal Rates S, And Diffusivity D – all of which are very poor for
traditional Spherical Balls. Thus Produce Much Lower Mass Transfer Rates
− Using Ellipsoidal Shapes, Bed And Tower Heights Can Be Reduced for Fixed Beds.
Unsurpassed Mass & Heat
Transfer
− Conventional fixed packing systems
are extremely limited in their mass &
heat transfer performance due to the
complicated laminar flow patterns
around packing shapes
− In the TS system these flow patterns
are broken down to decrease mass
transfer resistance & improve
gas/liquid mixing
SYSTEM OPERATING
DETAILS
TURBOSCRUBBER VENTURI/PACKED
TOWER
LIQUID MEDIUM SEAWATER OR
35% W/W KCI
SLURRIES
SEAWATER ONLY
SO2 REMOVAL 99.80% 99.80%
KCI/C PARTICULATE
REMOVAL @ 1.7
MICRON
99% 99%
PRESSURE DROP 6.4" W.G. 15" W.G.
RELATIVE VOLUME
(APPROX)
1 5
PLUGGING/CLOGGING NO YES
SLURRY HEAT
RECOVERY RATE
4.2MW NONE POSSIBLE
A Real Case Comparison of Equivalent Efficiency Systems
TOWER TYPE TURBOSCRUBBER FIXED PACK
PACKING TURBOID TYPICAL 2" RING
H2S REMOVAL 99.997 99.997
TYPICAL DIAMETER 1.25 METER 1.75 METER
ABSORBTION ZONE
HEIGHT 2 METERS 7 METERS (FIXED)
PRESSURE DROP
(APPROX) 6" W.G 6" W.G
A Real Case Comparison of Equivalent Efficiency Systems
Cut Costs & Emissions with a Non Foul High Efficiency Turbulent Bed:
− Dramatically Improve Underperforming Or Plugged Up Scrubber
− Technical Support & Pilot Trials Available
− Radically Improve Absorption Rates
− Low Height Maintenance Free Beds
− Submicron Particulate Removal
− Low DP Turbopak® /Turboid® Packing
− No Major Retrofit Modifications
− Just Replace Grids & Packing
− Maintain Recycle Pipework & Fan
− Guaranteed Non Plugging Beds
Engelhard, Metal Recovery, U.K.
Hercules BetzDearborn, Chemicals, U .K.
SPP/Suncor , Oil Recovery, Australia
Bartz, Metal Castings, Germany
MASS
TRANSFER
PARTICLE
TRANSFER
HEAT
TRANSFER
FLUID
DYNAMICS
TOWER
DESIGN
GAS
ABSORBED SO2 PARTICULATES
KCI salt
crystals and
fine carbon
(soot)
INLET GAS
TEMP. 174ºC
GAS FLOW-
RATE
50,000
m³/hr
COLUMN
DIA. 2.3m
LIQUID
MEDIUM
KCI / NaCI
Slurry or
Seawater
MEAN PARTICLE
SIZE 2.5 micron
% APPROACH
TEMP. 87%
OPERATING
MODE
Once
Throu'
OVERALL
HEIGHT 8.5m
INLET CONC. 300 ppm % REMOVAL 99%
HEAT
TRANSFER
RATE
4.1 MW PRESSURE
DROP 1600 Pa MOC
Mild
Steel,
Glass
flake
Coated
% ABSORBED 99.8%
TurboScrubber ® Unit Simultaneously:
− Scrubs fine KCl salt & soot particles
− Absorbs SO2 Gas, and
− Recovers over 4 MW of heat energy
MASS
TRANSFER
PARTICLE
TRANSFER
HEAT
TRANSFER
FLUID
DYNAMICS
TOWER
DESIGN
Gas
Absorbed HF Particulates Al2O3
Inlet Gas
Temp. 80ºC
Gas Flow-
Rate
260,000
Am³/hr
Colunm
Dim. 7m x 4m
Liquid
Medium
Water/Alkali
ne Solution
Mean Particle
Size 1.7 micron
% Aproach
Temp. 93%
Operating
Mode
Recycle/
Bleed
Overall
Height 30m
Inlet Conc. 50ppm % Removal 85%
Heat
Transfer
Rate
3600 kW Pressure
Drop 800 Pa MOC
Plastic
lined steel
% Absorbed 99%
− 6 large TS units - combined flow of 1.5 x106Am3/hr
− Considerably Cheaper Option than Bag Filters
− Simultaneously Remove:
Fine PM, Combustion Products & HF Gas
MASS
TRANSFER
PARTICLE
TRANSFER
HEAT
TRANSFER
FLUID
DYNAMICS
TOWER
DESIGN
Gas
Absorbed SO2 Particulates Na2 S2 O5
Inlet Gas
Temp. 60ºC
Gas
Flowrate
7000-
17000
m³/hr
Column
Dia. 1.15m
Liquid
Medium NaOH
Mean Particle
Size 1 micron
% Approach
Temp. 96%
Operating
Mode Recycle
Overall
Height 7.2m
Inlet Conc. 2000ppm % Removal 98%
Heat
Transfer
Rate
50 kW
(reaction)
Pressure
Drop
up to
3000 Pa MOC
PP, GRP
reinforced
% Absorbed 99.9%
− Simultaneously Scrubs Fine Sodium Metabisulfite Dust
And SO2 Gas, From Dryers, To High Efficiencies.
− Replacement And Upgrade For An Existing Packed
Scrubber (Prone To Blockage By The Precipitated
Solids)
MASS
TRANSFER
PARTICLE
TRANSFER
HEAT
TRANSFER
FLUID
DYNAMICS
TOWER
DESIGN
Gas
Absorbed SO2 Particulates
Fine Carbon
(soot) from
oil firing
Inlet Gas
Temp. 135ºC
Gas
Flowrate
41,000-
82,000
m³/hr
Column
Dia. 2.35m
Liquid
Medium
Process
Effluent
Mean Particle
Size 2 micron
% Approach
Temp. 98%
Operating
Mode
Recycle
with
variable
bleed &
make-up
Overall
Height 9.8m
Inlet Conc. 800ppm % Removal 97%
Heat
Transfer
Rate
400 kW
(typical)(4
MW
potential)
Pressure
Drop
1000 Pa
(typical) MOC
Mild Steel
Glass
Flake
coated
Outlet Conc.
Controlled
at 150 ppm
(typical)
− Simultaneously Scrubs Fine Soot, Absorbs SO2 Gas, &
Recovers Waste Heat.
− Uses Effluent Buffer Solution as the Scrubbing Medium
− Unique Non-clogging Feature Ensures Reliable &
Consistent Operation Without Increase in Gas Side DP
− NOx Scrubbing Systems - Operated With NaOH Or
Powerful Oxidant (H2O2).
− TS’s High Mass Transfer Performance Compact
Towers Minimise Space & CAPEX.
− Existing NOx Scrubbers Easily Retrofitted
− Tower to Right (N. France) retrofitted from fixed bed
(Pall rings)
Breakthrough Air Stripping Technology
− 100% Non-Clogging Water Clean-up Technology
− Low Profile Units Available
− Small Footprint
− Low Energy Consumption
− Easily adaptable for Off-Gas Treatment
− High Removal Rates of VOC's, Semi-Volatiles and Napthalenes
Over 200 Units Installed Worldwide
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