Electrostatic Precipitators

BCE electrostatic precipitators (ESP) are air pollution control devices which remove particulates from the air by using a high-voltage electric current to impart a negative electrical charge to the dust, which is then attracted to, and deposited on, positively charged plates in the unit.  BCE has engineered and installed electrostatic precipitators for a variety of installations and performs maintenance on existing ESPs.

The plates of ESP are cleaned by periodic or continuous rapping. Dust falls into the hopper(s) and is removed by a pneumatic conveying system. ESP's are primarily used to remove fly ash in coal-fired power plants, but can be used to remove dust from any application, and have also found use in the cement, chemical and paper industries. Depending on the application, precipitators are designed for efficiencies between 90% and 99.9%. Increasing the power input generally increases the efficiency. Particles over 1 micron can be collected with high efficiency, particularly when dust resistivity is low. Efficiency drops off rapidly for extreme submicron particles due to Brownian motion, or random collisions of particulates with air molecules.

Dust resistivity is a major factor in collection efficiency. The higher the resistivity, the more difficult it is for a particle to transfer its electrical charge. When a switch to low sulfur coal was made, it was discovered that many ESP's no longer met emissions standards to the high resistivity of low sulfur coal. This resulted in larger units to achieve the required efficiency. To reduce resistivity, conditioning agents have been added to flue gases. Sulfur trioxide has been used successfully with basic dusts such as fly ash and ammonia works well with acidic dusts.

Where a high efficiency can be achieved, an ESP is an attractive alternative to a fabric dust collector. Some advantages are:

• Operating temperatures up to 800°F
• No compressed air required
• Infrequent maintenance (no bags to replace)
• Lower pressure drop, therefore less power required to convey air

BCE will be happy to analyze your application with you to see whether an electrostatic precipitator in lieu of a baghouse may be advantageous.

http://benconeng.com/dust-collector-pollution-control-engineering/dust-collector-pollution-control-equipment/electrostatic-precipitators

Phone: 866-936-4286

Email: info@benconeng.com

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Wet Scrubbers

A wet scrubber is an air cleaning device where a dust-laden air stream is brought into contact with a scrubbing liquid (generally water) and the fine particulates are captured by the liquid droplets and, hence, removed from the air. Dirty water exits the device, but the cleaned air will still retain a fine mist. Therefore, it is necessary for a wet scrubber to have a second stage, called a mist eliminator, to remove these fine droplets. Wet scrubbers can also be used to absorb noxious constituents from the gas, but the design criteria for gas absorption can be quite different from that for particulate removal.

Wet scrubbers are classified as follows, based on unit pressure drop:

• Low energy scrubbers (< 5" W.G.)
• Medium energy scrubbers (5-15" W.G.)
• High energy scrubbers (>15" W.G.)

BCE Low energy scrubbers are used to collect particles greater than 5 microns. An example of this type is a spray tower. This is a cylindrical vessel fitted with rows of water pipes to spray down on rising inlet air. To prevent droplets from being entrained with the rising air stream, the droplet size must be relatively large (500-1000 microns) compared to high-energy scrubbers and the air velocity must be low (1-4 ft/sec). The larger droplets reduce efficiency and the low air velocity makes this type scrubber larger than others at the same air volume. Other types of low-energy scrubbers are orifice scrubbers and dynamic wet precipitators.

BCE High-energy wet scrubbers are used to collect submicron particles. Two common designs of high-energy wet scrubbers are the venturi scrubber and the packed tower, both designed to provide effective contact of water droplets with the dust-laden inlet air.

The BCE Venturi Scrubber, as the name implies, contains a converging section, throat and diverging section. Dust-laden air enters at the top of the converging section and the scrubbing liquid is injected either at the entrance of the converging section or at the throat. As a result of the area reduction from the venturi entrance to the throat, the air reaches a high velocity where it strips the water from the scrubber wall, forming countless numbers of very small droplets, which capture the particles in the venturi throat. The mist eliminator of a BCE Venturi Scrubber is usually a cyclonic separator directly coupled to the scrubber.

The packed tower consists of a single cylindrical vessel where the inlet air and water contact each other countercurrently in a packed bed and the mist eliminator is in the top of the vessel to remove the fine droplets before the cleaned air exits through the top outlet. Packed beds are commonly used in a variety of applications where a large area of contact is necessary to promote intimate contact between gas and liquid phases.

The following are some advantages and uses of BCE Wet Scrubbers:

• Can handle high-temperature gas streams
• Low initial cost
• Small space to install
• Separates explosive solids from gas streams
• Reduces temperature of exhaust stream
• Capable of high collection efficiency

Some disadvantages are:

• Discharge slurry must be dealt with as a water-disposal issue
• High collection efficiency requires a relatively large pressure drop, resulting in high energy consumption
• Erosion of the scrubber walls at high velocity
• Corrosion-resistant materials often necessary due to creation of possible acid solutions and for wet-dry interface areas

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Control Systems

BCE Control Systems manage, command, direct, and/or regulate multiple devices of a process system.  These Human Machine Interface (HMI) systems allow your system administrators to monitor and control system flow and status conditions from a touch screen computer in a monitoring room.  This allows your staff to focus time and resources on aspects other than pollution control by giving them a more flexible form of systems monitoring.

Contact BCE to learn more about our various HMI systems, and to find out how we can customize it to fit your installation or requirements.

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Below are some screen shots of our installed HMI systems:

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ASME Code Design

BCE designs, fabricates and installs recovery and contamination protection using ASME code design standards and practices, including BPVC and PTC.  In many chemical process industries, ASME high-pressure filter vessels are needed to recover product or protect downstream equipment from contamination. In addition, containment vessels, designed per NFPA 69 to contain dust explosions without external venting, have design pressures of 50 psig. At positive design pressures above 15 psig, unfired pressure vessels, such as bag filters, are required to be designed and built in accordance with the ASME Code, Section VIII. In order to receive the ASME "U" stamp, Code vessels must, amongst other Code requirements, meet the following:

• Be built in a Code shop.
• Pressure parts, including bolting, manufactured exclusively of Code quality materials and designed and sized according to applicable rules in the Code.
• Welding be per ASME Code, Section IX, by Code qualified welders.
• Receive a hydrostatic test after fabrication at 1.3 times the maximum allowable working pressure.
• Pass inspection by an accredited ASME Authorized Inspector.

Let BCE engineers design and install the right solution for your system.  Our engineers have extensive experience with designing according to the special requirements of the ASME Code. We can custom design any vessel to these requirements in even the most demanding environments, such as those found in the petrochemical industry. Call us and we will assist you in specifying one of these units.

Toll Free: 866-936-4286

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Industrial Ductwork

Industrial ductwork is an important component in any ventilation system.  Ductwork allows the particulates to to reach the baghouse, allowing the dust collector to function properly.  

BCE designs and fabricates custom ductwork to properly meet the specifications of the airflow system required at your facility.

BCE Industrial Ductwork Design, Fabrication and Installation

Our designers and engineers develop your system layout and designs to ensure the most cost-effective and reliable solution. Light to heavy gage industrial ductwork is designed to a variety of specifications.

We fabricate multiple forms of industrial ductwork using carbon steel, stainless steel, corrosion/heat resistant alloys, and galvanized/aluminized using cutting edge CAD design software and CNC machinery.

BCE's highly experienced installation engineers ensure a professional installation. Strategic and knowledgable planning results in minimal down-time of your project or system.

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Thermal Oxidizers

BCE thermal oxidizers are necessary when the processed air contains small, combustible particulates, these BCE thermal oxidizers may be used as a method of air pollution control. The idea of using a thermal oxidizer is to reduce toxic, explosive, or otherwise dangerous, pollutants to simpler, non-toxic substances by subjecting the pollutants to very high temperatures where the chemical bonds are broken. The decomposed material may then be released safely to the atmosphere.  BCE prides itself on creating optimum clean air solutions for you and your project.

BCE thermal oxidizers may be classified as follows:

• RegenerativeIn a regenerative thermal oxidizer (RTO), energy used in the oxidation process is recovered very efficiently by ceramic heat transfer beds coupled to the oxidation chamber. Thermal efficiency can be around 95% for this type of oxidizer. A disadvantage is the expense of replacing the ceramic media in case of plugging. Also RTO's often run at higher pressure drops than recuperative oxidizers.
   
• RecuperativeIn a recuperative thermal oxidizer, heat from oxidation is passed through a heat exchanger which in turn heats the inlet air. Energy recovery for this type is roughly 70%. Although the recuperative oxidizer costs less, the energy usage can be about six times that of an RTO, offsetting the savings over the long term.
   
• CatalyticA catalytic recuperative thermal oxidizer uses a catalyst such as platinum or rhodium to allow decomposition at a much lower temperature, bringing the operating temperature of the unit down from 1400°F to about 650°F. This reduces the fuel usage to about a quarter of the recuperative thermal oxidizer, but is still higher than that for the RTO.

BCE is ready to discuss your application with you. We will provide initial and operating cost estimates for the different types of thermal oxidizers so you can be sure you are getting the right oxidizer for your specific needs.

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Dust Collectors

BCE offers the following types of dust collectors, engineered to suit your process:

BCE has standard lines of bag filters, ranging from 9 to 420 bags, predesigned for competitive pricing and quick turn-around. Standard pressure ratings are ±20" W.G. for flat-walled collectors and up to 17" Hg for round units. See these pages for descriptions and general drawings of BCE standard fabric filter dust collectors:

• C-Series: Cylindrical, 7 to 154 bags, up to ±17" Hg design
• S-Series: Square, 9 to 400 bags, ±20" W.G. design
• R9-Series: Rectangular, 126 to 234 bags, 9-bags deep, ±20" W.G. design
• R14-Series: Rectangular, 252 to 420 bags, 14-bags deep, ±20" W.G. design

Where custom collectors are needed, BCE is fully capable to design, build and install everything from single units to entire systems, specific to your application. If high-pressure units are required, our engineers have decades of combined experience designing dust collectors to the ASME Code, Section VIII, Divisions 1 and 2. Call us to discuss your requirements. 

Pleated Filters:

For many applications where the dust is free-flowing and non-agglomerating, a collector with 6" diameter pleated filters is an economical choice over a bag filter. Although pleated filters operate at lower air-to-cloth ratio than bag filters, the large filter area per element typically results in a significantly smaller housing size. Call BCE and we will be happy to discuss whether a pleated filter is right for your application.

Cartridge Filters:

Large cartridge filters are ideal for low-temperature applications with a small dust loading and large air volume. As with pleated filters, cartridges provide a large filter area per element resulting in a compact unit, requiring much less headroom than a bag filter of comparable capacity. BCE uses a downflow design to promote dust settling and maximize the air-to-cloth ratio.

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Fabric filter dust collectors are the equipment of choice to remove fine particulates from air with the efficiency to satisfy EPA regulations. In addition to their extremely high efficiency, they are easy to maintain, having no moving parts, and are very versatile with a wide range of fabrics available for just about any dust type, loading or process environment.

Dust-laden air enters the baghouse through one or more inlet nozzles. The air velocity drops, allowing larger particles to fall out of the air stream into the hopper. Dust is further separated when the air contacts a baffle, which serves to distribute the air, deflect dust into the hopper and protect the filter elements from direct, high-velocity, dust impingement. Fine particles are carried into the bag area and deposited on the exterior surfaces of the filters, as the cleaned air passes through to the insides of the bags and into the clean air plenum, leaving the collector through the outlet nozzle(s). The fabric provides a surface on which the dust collects and the operating efficiency is achieved when a sufficient dust cake forms, reducing permeability.

The filters are cleaned row-by-row when a short burst of compressed air fills a blowpipe above a row of bags, exiting the pipe through a series of orifices, one over each bag. Each bag is fitted with a venturi, designed to draw in air from the clean air plenum to create a powerful pneumatic shock, pressurizing the bag. The shock wave travels down the length of the bag and the dust is dislodged by the combined actions of flexing the bag and reversing the air flow. The dust falls into the hopper for removal by the discharge equipment. The cleaning pulse is extremely rapid (about 100 msec.) and only affects a fraction of the collector's overall filter area, allowing for continuous on-line operation. The efficiency of the cleaning pulse also allows pulse-jet filters to operate at higher air-to-cloth ratios than mechanical shakers or reverse-air collectors. 

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EPollution control equipment installation, especially on a large project, is an art involving many crafts, specialists and equipment. It can be difficult and time-consuming, sometimes lasting weeks or even months. Most OEM’s don’t even attempt to install their equipment, let alone large systems. However, at BCE, we take a different approach. We are as comfortable providing a simple bin vent as designing, building and installing a multi-million dollar turnkey pollution control system. So if your needs demand a single-source supplier who will take the project from conception to start-up, give BCE a call!quipment and Turnkey System Installation

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Structural Steel

BCE designs, fabricates and installs structural steel for a variety of uses and industries. Our welders are certified and product top quality work. We can take a structural steel project from conception to completion providing any level of support required. We have licensed experienced structural engineers and draftsmen ready to work on your project.

Electrostatic Precipitators

BCE electrostatic precipitators (ESP) are air pollution control devices which remove particulates from the air by using a high-voltage electric current to impart a negative electrical charge to the dust, which is then attracted to, and deposited on, positively charged plates in the unit.  BCE has engineered and installed electrostatic precipitators for a variety of installations and performs maintenance on existing ESPs.

The plates of ESP are cleaned by periodic or continuous rapping. Dust falls into the hopper(s) and is removed by a pneumatic conveying system. ESP's are primarily used to remove fly ash in coal-fired power plants, but can be used to remove dust from any application, and have also found use in the cement, chemical and paper industries. Depending on the application, precipitators are designed for efficiencies between 90% and 99.9%. Increasing the power input generally increases the efficiency. Particles over 1 micron can be collected with high efficiency, particularly when dust resistivity is low. Efficiency drops off rapidly for extreme submicron particles due to Brownian motion, or random collisions of particulates with air molecules.

Dust resistivity is a major factor in collection efficiency. The higher the resistivity, the more difficult it is for a particle to transfer its electrical charge. When a switch to low sulfur coal was made, it was discovered that many ESP's no longer met emissions standards to the high resistivity of low sulfur coal. This resulted in larger units to achieve the required efficiency. To reduce resistivity, conditioning agents have been added to flue gases. Sulfur trioxide has been used successfully with basic dusts such as fly ash and ammonia works well with acidic dusts.

Where a high efficiency can be achieved, an ESP is an attractive alternative to a fabric dust collector. Some advantages are:

• Operating temperatures up to 800°F
• No compressed air required
• Infrequent maintenance (no bags to replace)
• Lower pressure drop, therefore less power required to convey air

BCE will be happy to analyze your application with you to see whether an electrostatic precipitator in lieu of a baghouse may be advantageous.

http://benconeng.com/pollution-control-manufacturing/bce-manufactured-equipment/electrostatic-precipitators

Wet Scrubbers

A wet scrubber is an air cleaning device where a dust-laden air stream is brought into contact with a scrubbing liquid (generally water) and the fine particulates are captured by the liquid droplets and, hence, removed from the air. Dirty water exits the device, but the cleaned air will still retain a fine mist. Therefore, it is necessary for a wet scrubber to have a second stage, called a mist eliminator, to remove these fine droplets. Wet scrubbers can also be used to absorb noxious constituents from the gas, but the design criteria for gas absorption can be quite different from that for particulate removal.

Wet scrubbers are classified as follows, based on unit pressure drop:

• Low energy scrubbers (< 5" W.G.)
• Medium energy scrubbers (5-15" W.G.)
• High energy scrubbers (>15" W.G.)

BCE Low energy scrubbers are used to collect particles greater than 5 microns. An example of this type is a spray tower. This is a cylindrical vessel fitted with rows of water pipes to spray down on rising inlet air. To prevent droplets from being entrained with the rising air stream, the droplet size must be relatively large (500-1000 microns) compared to high-energy scrubbers and the air velocity must be low (1-4 ft/sec). The larger droplets reduce efficiency and the low air velocity makes this type scrubber larger than others at the same air volume. Other types of low-energy scrubbers are orifice scrubbers and dynamic wet precipitators.

BCE High-energy wet scrubbers are used to collect submicron particles. Two common designs of high-energy wet scrubbers are the venturi scrubber and the packed tower, both designed to provide effective contact of water droplets with the dust-laden inlet air.

The BCE Venturi Scrubber, as the name implies, contains a converging section, throat and diverging section. Dust-laden air enters at the top of the converging section and the scrubbing liquid is injected either at the entrance of the converging section or at the throat. As a result of the area reduction from the venturi entrance to the throat, the air reaches a high velocity where it strips the water from the scrubber wall, forming countless numbers of very small droplets, which capture the particles in the venturi throat. The mist eliminator of a BCE Venturi Scrubber is usually a cyclonic separator directly coupled to the scrubber.

The packed tower consists of a single cylindrical vessel where the inlet air and water contact each other countercurrently in a packed bed and the mist eliminator is in the top of the vessel to remove the fine droplets before the cleaned air exits through the top outlet. Packed beds are commonly used in a variety of applications where a large area of contact is necessary to promote intimate contact between gas and liquid phases.

The following are some advantages and uses of BCE Wet Scrubbers:

• Can handle high-temperature gas streams
• Low initial cost
• Small space to install
• Separates explosive solids from gas streams
• Reduces temperature of exhaust stream

http://benconeng.com/pollution-control-manufacturing/bce-manufactured-equipment/wet-scrubbers

Thermal Oxidizers

BCE thermal oxidizers are necessary when the processed air contains small, combustible particulates, these BCE thermal oxidizers may be used as a method of air pollution control. The idea of using a thermal oxidizer is to reduce toxic, explosive, or otherwise dangerous, pollutants to simpler, non-toxic substances by subjecting the pollutants to very high temperatures where the chemical bonds are broken. The decomposed material may then be released safely to the atmosphere.  BCE prides itself on creating optimum clean air solutions for you and your project.

BCE thermal oxidizers may be classified as follows:

• RegenerativeIn a regenerative thermal oxidizer (RTO), energy used in the oxidation process is recovered very efficiently by ceramic heat transfer beds coupled to the oxidation chamber. Thermal efficiency can be around 95% for this type of oxidizer. A disadvantage is the expense of replacing the ceramic media in case of plugging. Also RTO's often run at higher pressure drops than recuperative oxidizers.
   
• RecuperativeIn a recuperative thermal oxidizer, heat from oxidation is passed through a heat exchanger which in turn heats the inlet air. Energy recovery for this type is roughly 70%. Although the recuperative oxidizer costs less, the energy usage can be about six times that of an RTO, offsetting the savings over the long term.
   
• CatalyticA catalytic recuperative thermal oxidizer uses a catalyst such as platinum or rhodium to allow decomposition at a much lower temperature, bringing the operating temperature of the unit down from 1400°F to about 650°F. This reduces the fuel usage to about a quarter of the recuperative thermal oxidizer, but is still higher than that for the RTO.

BCE is ready to discuss your application with you. We will provide initial and operating cost estimates for the different types of thermal oxidizers so you can be sure you are getting the right oxidizer for your specific needs.

http://benconeng.com/pollution-control-manufacturing/bce-manufactured-equipment/thermal-oxidizers