ENGINEERING

Dust Collection and Pollution Control System Engineering

BCE's engineering staff is highly experienced and provides a variety of services for a wide range of industries. We specialize in engineering, manufacturing, and installing dust collectors, thermal oxidizers, baghouses, and an array of other advanced pollution control formats.

Local and global attention towards pollution and nuisance control in many industrial applications has been increasing over time, making control of released particulates an important issue for any business or entity.

This calls for the proper design, installation, and maintenance of dust collection equipment, whether toxic or not, because particulate containment is a must to provide a healthy and clean environment.

We are experienced developers of complete turnkey dust collection systems and we are ready to design a system for you!

If you have any questions about our services or capabilities, please contact us via phone, e-mail, or use our online form. 

EQUIPMENT

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SOLUTIONS

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BCE: ENGINEERING, MANUFACTURING, MAINTENANCE

The Advantage of BCE Dust Collector Systems

BCE is the world leader in dust collector and pollution control equipment design, manufacturing, installation, maintenance and parts supply.

We are your one stop shop for all things related to pollution control and the engineering systems that are associated with product recovery and material handling.

Baghouse and Cyclone Pollution Control Systems

We have designed, fabricated, installed and continue to maintain, a variety of systems using our cutting-edge technologies that fully automate entire pollution control and product recovery systems. Our systems are second to none. Our innovation has led us to design, build and install the cleanest and most technologically advanced pollution control system for a coal fired boiler ever! Our stack is cleaner than a hospital surgery room! A world first! Our multi-disciplined team has the knowledge, experience and foresight to handle the most challenging pollution control projects. With BCE’s attention to quality, you will receive the optimal solution for your application.

Dust Collector Maintenance and Installation Experts

BCE has wide-ranging experience in the dust collector engineering and pollution control manufacturing industries.

We have a full line of standard dust collectors and baghouse systems; we also supply custom designed units for a variety of pollution control applications. We also offer replacement parts for most baghouses,thermal oxidizers and other pollution control equipment.

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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. 

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ESP MANUFACTURING

Electrostatic Precipitator Manufacturing

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.

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Wet Scrubber Manufacturing

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.

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

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Thermal Oxidizer Manufacturing

BCE thermal oxidizers are necessary when the processed air contains small, combustible particulates.  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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Multiclone Manufacturing

BCE multiclones effectively remove large to moderate sized particles from air streams for recovery or disposal by means of centrifugal forces.

Air flows through the cylindrical tubes at high speeds creating centrifugal forces that cause the solid material to cling to the outer surface and continue a downward spiral separating out while clean air exits through the center.  

Multiclones may be used alone or in conjunction with another dust collector or after-filter device. BCE is highly experienced with multiclones, cyclones, and many other forms of dust collection and air filtration.

Feel free to contact us by phone, e-mail, or by using the form our contact form.

        



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Cyclone Dust Collector Manufacturing

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3/18 - BCE Equipment Manufacturing And Fabrication

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Centrifugal separators, or cyclones, are the most commonly used types of dust collection equipment.  They are simple to manufacture, inexpensive and have no mechanical or pneumatic components and, unlike conventional baghouses, can operate at temperatures over 1000°F.  

Dust-laden air enters a cyclone tangentially.  As the main vortex spirals downward, the coarser particles move to the wall, due to inertia, and are discharged through the hopper.  An inner vortex forms in the cone and spirals upward and out of the cyclone, carrying finer particles with it.  Cyclones are often used to remove larger particles from the air stream ahead of a baghouse in order to reduce the dust loading.

The major drawback of a cyclone is its low efficiency for respirable particulates (< 5 microns), although efficiency increases markedly at high dust concentrations and for agglomerating dusts.  If the material is especially abrasive, the walls are subject to erosion, in which case abrasion-resistant construction, replaceable inlet scroll or a liner may be indicated.  It should not be used for sticky dusts.

BCE offers single and multiple types of cyclone dust collectors.  Multiple cyclone collectors include dual and quad as well as multiclones, which feature a large number of small cyclones operating in parallel with a common inlet and outlet.

Get started with BCE

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