UNIT 5

UNIT OPERATIONS FOR AIR

POLLUTION CONTROL
Industrial dust removing equipment; Electrostatic precipitators; Cyclone;
Bag filters; Scrubbers.
Electrostatic Separation
• Principle : If one or more of the materials of a granular mixture can
acquire a surface charge on or just before entering an electrostatic field,
the grains/particles of that material will be attracted towards the active
electrode or repelled from it depending upon the sign of the charge on
the grains/particles.
• Electrostatic separation is a method of separation of solid particles
based on the differential attraction or repulsion of charged particles
under the influence of an electric field.
• Basically, the difference in electrical properties of different materials is
responsible for such a separation.
• Charging of particles is an essential step in this separation.
• Solid particles can receive a surface charge by any one of the following
methods : (i) Contact electrification. (ii) Electrification by conductive
induction. (iii) Electrification by bombardment.
Electrification by conductive induction
• When an uncharged solid particle is placed on a grounded conductor in the
presence of an electric field (i.e., when it comes in contact with a charged
surface), the particle will rapidly acquire a surface charge by induction.
• A conductive particle acquires the same charge as the grounded conductor
(it becomes charged to the same potential as the grounded conductor
within a very short period of time) through its contact with the conductor
while a dielectric particle is polarised and thus no net charge is generated
on it.
• As a consequence of this induction, the conducting particle will be repelled
by the surface/grounded conductor, while the dielectric particle will be
unaffected. This method is used for making a finite separation between
relative conductors and non-conductors.
Electrostatic separation
• Depends on differences in the electrical properties
(conductivity) of the materials to be treated.
• consists of a grounded rotor/rotating drum, a hopper
for feeding the solids, an active electrode,
situated/placed at a small distance from the drum and
collecting bins.
• The solids to be separated are fed on to a rotating
drum, either charged or grounded, from a hopper.
• The conductive particles in a very short time will
assume the potential of the rotating drum, which is
opposite to that of an active electrode and hence,
they get attracted towards the active electrode.
• The non-conductive material is repelled by the
electrode and attracted by the drum. The non-
conductive material falls down straight under the
influence of gravity and is collected in a separate bin.
A cyclone/cyclone separator
• They offer one of the least expensive
means of dust collection (separation of
dust particles from gases).
• They utilize a centrifugal force to effect the
separation which depends on particle size
and/or on particle density. Thus, cyclones
are used to effect a separation on the basis
of particle size or particle density or both.
• Cyclone separators is one of many air
pollution control devices known
as precleaners since they generally remove
larger pieces of particulate matter.
• This prevents finer filtration methods from
having to deal with large, more abrasive
particles later on. In addition, several
cyclone separators can operate in parallel,
and this system is known as
a multicyclone.
• It consists of a tappering cylindrical vessel, i.e., a cylindrical
vessel consisting of a top vertical section and lower
conical/tappering section terminating in an apex opening - a
short vertical cylinder which is closed by a flat plate on top
and by a conical
• It is provided with a tangential feed inlet nozzle in the
cylindrical section near the top and an outlet for the gas,
centrally on the top.
• The outlet is provided with a downward extending pipe - a
pipe that extends inward into the cylindrical section - to
prevent the gas short-circuiting directly from the inlet to the
outlet and for cutting the vortex.
• In this separator, used for the separation of dust particles or
mist from gases, the dust laden gas is introduced tangentially
into a cylindrical vessel at a high velocity (30 m/s).
• Centrifugal force throws the solid particles out against the
wall of the vessel and they drop into a conical section of the
cyclone and removed from the bottom/apex opening. The
clean gas is taken out through a central outlet at the top.
• Cyclones are widely used for collecting heavy and coarse
dusts. These units may also be used for separating coarse
materials from fine dust.
Bag filters
• A BAG FILTER is a system used to enhance the quality
of air released from industrial and commercial
processes by collecting dust and other impurities
from air or gas.
• Designed to handle high-volume dust loads, a BAG
FILTER system consists of a blower, dust filter, a filter-
cleaning system, and a dust receptacle or dust
removal system. It is distinguished from air
purifiers, which use disposable filters to remove dust.
• Unlike electrostatic precipitators, where
performance may vary significantly depending on
process and electrical conditions, functioning bag
filters typically have a particulate collection efficiency
of 99% or better, even when particle size is very small
Where are these BAG FILTERs are employed?

• Bag Filters are employed in cement industry as a process bag filter

either in raw mills, kiln or cement mills.
• Bag filters are also installed in places, which cleans the dust laden air
from the suction points specially in transfer points and leaves out
clean air into the atmosphere
 Operation
• Bag filters use long, cylindrical bags (or tubes) made of woven or felted fabric as a filter medium. For applications where
there is relatively low dust loading and gas temperatures, pleated, nonwoven cartridgesare sometimes used as filtering
media instead of bags.
• Dust-laden gas or air enters the bag filters through hoppers and is directed into the bag filters compartment. Thegas is
drawn through the bags, either on the inside or the outside depending on cleaning method, and a layer ofdust
accumulates on the filter media surface until air can no longer move through it.
• When a sufficient pressure drop (ΔP) occurs, the cleaning p rocess begins. Cleaning can take place while the bag filters is
online (filtering) oris offline (in isolation). When the compartment is clean, normal filtering resumes.Bag filters are very
efficient particulate collectors because of the dust cake formed on the surface of the bags.The fabric provides a surface
on which dust collects through the following four mechanisms:
• Inertial collection Dust particles strike the fibers placed perpendicular to the gas-flow direction instead of changing direction with
the gas stream.
• Interception Particles that do not cross the fluid streamlines come in contact with fibers because of the fiber size.
• Brownian movement – Submicrometre particles are diffused, increasing the probability of contact between the particles
and collecting surfaces.
• Electrostatic forces The presence of an electrostatic charge on the particles and the filter can increase dust capture.
• A combination of these mechanisms results in formation of the dust cake on the filter, which eventually increases the
resistance to gas flow. The filter must be cleaned periodically.
TYPES OF BAG FILTERS
• Bag filters are classified by the cleaning method used. The three most common types of bag
filters are mechanical shakers, reverse gas, and pulse jet.
• Mechanical shaker Bag filters
• In mechanical-shaker bag filters, tubular filter bags are fastened onto a cell plate at the
bottom of the bag filters and suspended from horizontal beams at the top. Dirty gas enters
the bottom of the bag filter and passes through the filter, and the dust collects on the inside
surface of the bags. Cleaning a mechanical-shaker bag filter is accomplished by shaking the
top horizontal bar from which the bags are suspended. Vibration produced by a motor-
driven shaft and cam creates waves in the bags to shake off the dust cake.
• Mechanical-shaker bag filter range in size from small, hand shaker devices to large,
compartmentalized units. They can operate intermittently or continuously. Intermittent
units can be used when processes operate on a batch basis; when a batch is completed, the
bag filters can be cleaned. Continuous processes use compartmentalized bag filters; when
one compartment is being cleaned, the airflow can be diverted to other compartments. In
mechanical-shaker bag filters, there must be no positive pressure inside the bags during the
shake cycle.
• Pressures as low as 5 pascals (0.00073 psi) can interfere with cleaning. The air-to-cloth
ratio for mechanical-shaker bag filters is relatively low, hence the space requirements are
quite high. However, because of the simplicity of design, they are popular in the minerals
processing industry.
Reverse air bag filters
• In reverse-air bag filters, the bags are fastened onto a cell plate
at the bottom of the bag filters and suspended from an
adjustable hanger frame at the top. Dirty gas flow normally
enters the bag filters and passes through the bag from the
inside, and the dust collects on the inside of the bags.
• Reverse-air bag filters are compartmentalized to allow
continuous operation. Before a cleaning cycle begins, filtration is
stopped in the compartment to be cleaned. Bags are cleaned by
injecting clean air into the BAG FILTER in a reverse direction,
which pressurizes the compartment.
• The pressure makes the bags collapse partially, causing the dust
cake to crack and fall into the hopper below. At the end of the
cleaning cycle, reverse airflow is discontinued, and the
compartment is returned to the main stream. The flow of the
dirty gas helps maintain the shape of the bag.
• However, to prevent total collapse and fabric chafing during the
cleaning cycle, rigid rings are sewn into the bags at intervals.
• Space requirements for a reverse-air bag filters are comparable
to those of a shaker bag filters; however, maintenance needs are
somewhat greater.
Pulse jet air bagfilters
• use compressed air pulses to dislodge dust from the filter bags:
• Dust collection: Dirty air enters the filter through a port at the bottom,
where a baffle plate blocks large particles and directs them to a
hopper. Smaller particles are carried into the filter bags.
• Filter cake formation: As filtration continues, a dust cake forms on the
filter bags.
• Compressed air pulses: A controller activates a series of compressed air
pulses into the filter bags at a timed interval or based on pressure
drop. The pulses are typically 100–200 microseconds long.
• Shock wave: The compressed air pulses create a shock wave that travels
through the filter bags in the opposite direction of the normal
airflow. This shock wave, combined with the induced draft of air
through a venturi nozzle, dislodges the dust from the filter bags.
• Dust removal: The dust falls into the hopper for removal.
• Clean air: Clean air enters the upper chambers of the filter and exits
through the outlet.
Scrubbers
• pollution control devices which are using
liquid to wash unwanted pollutants from a
gas stream. Scrubber systems such as
chemical scrubbers, gas scrubbers are a
diverse group of air pollution control
devices.
• Scrubbers remove the unwanted gases and
particulate matter from industrial
smokestacks before they enter
the atmosphere.
• Actually, in the scrubber system, the exhaust
gas is passed in the column from downside
and scrubbing solution/material is sprayed
at top. Here Liquid-Gas i.e. wet scrubber or
Gas-Solid powder i.e. dry scrubber
operation takes place.
 Working of Scrubber
• A scrubber is a cleaning installation whose main purpose is to neutralize harmful components in
industrial air or waste gas streams. The removal of gas particles causing many problems from the gas
stream during the process is necessary before disposing of the gases in the open air.
• In some cases, the use of a gas scrubber may allow recovering certain raw materials after the
treatment. A big advantage is the versatility of a gas scrubber in different areas. It includes the
chemical industry, the pharmaceutical industry, and surface treatment.
• The installation functions by bringing a gas stream in contact with a washing liquid. Due to this contact,
certain gaseous components dissolve and remain in the water.
• There is a transfer of the components from the gas phase to the liquid phase. This is
the absorption process. The solubility of the elements in the liquid will determine to what extent the
gaseous components dissolve into the liquid phase.
• Thus it is of great importance to work with the correct fluid being as the absorption agent. Also
besides the water, several organic or inorganic washing liquids can also be used for this purpose.
• In these cases, certain chemicals or micro-organisms are added to the washing liquid in order to
convert or neutralize the dissolved gases.
• More strict measures are taken in terms of allowed air pollution. Companies are being encouraged to
take the necessary measures about it. Gas scrubbers are essential in industries where employees face
exposed to potentially contaminated gases.
• When we use a scrubber in an optimal manner, we can achieve a very high removal efficiency of the
harmful gas particles. Therefore the fumes released in the outside air are no longer damaging to the
environment.
Types
• Wet and Dry scrubbers