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BoldEco Environment - Air pollution control solutions
Designing and Upgrading Air Pollution Control Equipment Using Modern Analytical Tools
Joseph Riley, Managing Director
Maurizio Archetti, Technical Director
BoldEco Environment, NJ, USA
Introduction
To those in the market for process equipment, a performance guarantee is probably as important as price. In the case of standardized equipment, it is usually enough to rely on the supplier’s experience in order to be satisfied with his ability to achieve a particular level of performance. In the case of a custom engineered system, and especially in more demanding applications, not only must the supplier have had previous experience in a similar application, but he must be able to evaluate the critical design conditions of the particular application in order to properly modify his basic design. In the case of air pollution control systems, it is imperative that not only the company responsible for executing the order have the experience, but that the it also have the experienced staff who can make distinctions about the very important and often overlooked differences between the reference projects and the one at hand. Only with this knowledge can he properly modify his design to achieve the guaranteed level of performance.
As pollution regulations become more stringent, the ability to modify a particular base design to meet the stricter levels of emissions becomes harder and harder to do with experience and traditional methods of calculation alone. It is therefore advantageous to implement the latest prediction and calculation tools available in order to achieve a higher degree of certainty of meeting the desired emissions levels and operational requirements.
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Application of modern analytical tools
The use of modern analytical tools such as Computation Fluid Dynamics (CFD) or physical modeling for the design of gas collection equipment is not new. Air pollution control companies have used physical modeling for large electrostatic precipitator dust collectors, especially when the pollution control apparatus has to be integrated into the network of ducting as specified by the engineer.
The state-of-the-art of flow modeling is such that most gas flow analysis companies that once only offered physical modeling, now offer CFD as an option. This came about as a result of many years of CFD implementation, not only in the high tech industries, such as aerospace and biomedical, but also in the basic industries, such as cement, steel, power, etc. This general acceptance by even the harshest critics means that CFD has become the de-facto standard for modeling gas flows, as well as chemical reactions, capture efficiency, droplet evaporation, gas mixing and other modeling tasks due to its lower cost, speed of results, and ease of model modification.
The implementation of CFD technology in many of the components used in air pollution control systems has traditionally been relegated to the simpler modeling tasks, such as spray tower and EP flow distribution, cyclone collection efficiency, gas-gas interaction (such as reactions, and cooling) and fan design. These exercises have traditionally been applied after the installation of the systems when problems have arisen that are at least potentially attributable to problems with a particular flow field. It is rare, with the exception of research and development efforts or the design of standard series equipment, that CFD be used habitually in the design of new, custom engineered electrostatic precipitators, fabric filters, spray towers, scrubbers, and other gas flow treatment apparatus used in air pollution control systems.
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BoldEco philosophy
BoldEco made the decision that it would acquire in-house CFD capabilities in order to aid in the design of its own equipment, as well as to improve the operation of competing or related systems, and as part of the consulting services offered to its customer base. BoldEco has invested in the tools required to apply CFD technology to the study of its custom engineered and standard air pollution control equipment. We believe that this capability will provide BoldEco with a decided advantage over its competition, as well as advance the state-of-the-art of various air pollution control technologies. By bringing these advanced tools in-house, we can provide our designers and engineers with the latest technological advancements, thereby ensuring the highest probability of a job well done while maintaining our competitive edge.
Equipment design
BoldEco uses CFD to optimize the design of various standard and custom equipment designs:
• Scrubbers
• Fabric filters
• EPs
• Spray towers
• Heat Exchangers
The principle of operation of each component is analyzed in depth by our fluid mechanics, and each finding is used to refine the base design. For each project or to solve a particular problem with an existing system, CFD is employed to determine what the flow might look like and is any flow-based corrections are warranted. These solutions are then; either incorporated into the design of the new equipment, or are presented to the client for implementation.
www.boldeco.com fabric filters dust collector ESP pulsejet conversion baghouse spray evaporative cooling gas conditioning spraying system dual-fluid air atomized nozzle gas flow CFD process analysis heat exchanger air-to-air gas cleaning filtration so2 so3 h2so4 caco3 ca(oh)2 gaseous dry scrubber wet venturi turnkey smokestack nuisance pjff pulse jet pulsejet pulse-jet self-cleaning non-fouling industrial utility centrifugal custom fan axial materials handling pulse timer pulse controller sequencer vento automatic voltage controller AVC rigid discharge electrode bha elex reverse air sub-micron submicron sub micron small particle size aerosol BoldEco Environment Eco Spray Tech Eco Environment Ecology low-energy nozzle dual-fluid air-atomized LEC limestone scrubber emission control CFB circulating fluid bed TFB turbulent fluid bed
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