Fly ash scrubbing in a novel dual flow scrubber

Scrubbers are used as particulate emission control devices with the increase in stringency of old regulations or promulgation of new regulations. Scrubbing of fly ash in a novel dual flow scrubber, i.e., one water filled bubble section and one section with water-spray, is reported in this article. The presented system included a tapered section in order to achieve the bubble regime. On the other hand, a two-phase critical flow atomizer was used for the generation of spray regime with high degree of spray uniformity. Experiments were carried out for studying the behavior of the system in terms of various pertinent variables. The fly ash removal mechanism was explained in terms of various physical interactions. Electrostatic effect was found to have an insignificant influence on the collection efficiency of fly ash. The removal efficiency was found to decrease with the increase in inlet fly ash loading in the bubble section while it was increased in the spray section. A compromise must, therefore, be struck while operating the scrubber for achieving the desired performance. The effects of other operating variables studied on the removal efficiency remained similar in the regimes under investigation. The combined effect was, however, that the spray regime was dominating. Experimentation also revealed that the bubble section collected particles down to 20 microm size. Detailed experimentation revealed that almost 100% removal efficiency (zero penetration) of fly ash could be achieved in the dual flow scrubber at a QL/QG ratio of 3.0 m3/1000 ACM (actual cubic meter). Almost zero penetration of fly ash particles, clearly demonstrated that the dual flow scrubber with its staging operations met with the stricter emission regulations for particulate matter. Selection of any particulate control device is intrinsically related to the performance as a function of various pertinent variables of the system. Correlations were, therefore, put forward for the prediction of the performances of the bubble and the spray sections in terms of various pertinent variables of the system. The overall removal efficiency achievable in the dual flow scrubber was predicted with the help of these correlations. The predicted values were in excellent agreement with the experimental values (well within +/-5.0% deviation). Comparison of the performance of the present system with the existing systems indicated that the bubble and spray sections either alone or in combination (as in a dual flow scrubber), was energy and efficiency-wise much better than the existing systems. The novelty of the system is also described.