When determining the size of a precipitator, the volume of process gas plays a crucial role. However, given that actual operations can be influenced by operational adjustments and environmental factors, it’s not always possible to predict outcomes accurately. To ensure smooth equipment operation, a margin or additional capacity for future expansion should be incorporated during design. If the system operates under atmospheric conditions, selecting a dust collector capable of handling ambient air is essential. Choosing a smaller air volume must align with environmental standards for controlling dust sources and emissions. While some argue against using multiple small dust collectors in parallel for atmospheric applications, this approach is often the least cost-effective.
When selecting a bag filter, the distribution of dust particles significantly impacts performance. Even with similar dust dispersion levels, operating conditions can vary. When choosing a dust collector, understanding the degree of dispersion is key, as it guides the appropriate selection. For instance, electrostatic precipitators are ideal for dust particles typically below a few microns, while cyclone collectors work well for larger particles above 10 microns. Besides dispersion, other factors like the dust collector's performance charts should guide the initial decision. Dust collectors dealing with low bulk density dust often face challenges in separation and collection, leading to increased secondary dust dispersal. This requires specialized handling and structural adjustments.
Cyclone dust collectors tend to achieve higher removal efficiencies with increasing inlet dust concentrations, but this also raises outlet concentrations. Thus, focusing solely on removal efficiency can be misleading. Wet dust collectors generally operate best with initial dust concentrations of around 10 g/m³ or less. Bag filters perform optimally at lower dust concentrations, though they can still meet environmental standards even at higher concentrations, provided they maintain consistent ash removal, manage pressure loss, and control discharge concentrations.
The specific resistance of an electrostatic precipitator depends on the temperature and humidity of the dusty gas. Ideally, this resistance should fall within the range of 10ⴠto 10¹ⰠΩ·cm. For the same type of dust, the resistance peaks between 100-200°C. Conditioning the dusty gas with sulfur reduces resistance, so when choosing an electrostatic precipitator, it’s vital to consider dust resistance, along with the temperature and conditioning of the gas.
Smaller dust particles have larger surface areas and absorb more moisture, enhancing adhesion. Cyclone collectors risk blockages due to adhered dust caused by centrifugal forces, whereas bag filters efficiently filter out adhered dust without clogging.
Most wet dust collectors use water to remove harmful gases and capture fine dust like carbon black and lead powder. If the dust source is small, the dust collector can be appropriately scaled down. Sewage management and preventing secondary pollution are critical considerations. When treating flue gas containing carbon monoxide, introducing air into the high-temperature section of the duct can convert CO to COâ‚‚, preventing explosions.
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