Dustex Corporation

Kennesaw, Georgia and Rocky MT,NC

Dustex Turkey

Corporate History
Dustex Corporation
Dustex was founded in 1947 as a division of American Precision Industries

Dustex initially entered into the market providing specialty cyclones for food and chemical processing
Dustex holds 18 APC equipment patents

Corporate Overview
Dustex Corporation
Dustex is incorporated in North Carolina
Privately-held company with ownership active in management and project execution Dustex maintains three office locations
Corporate headquarters located in Kennesaw, Georgia Automation/Controls/Aftermarket Division located in Acworth, Georgia Fabrication Division located in Rocky Mount, NC

Captive Fabrication Shop in Kingston, OH

Dustex Product Lines

Pulse Jet and Reverse air baghouses Dustex enhanced design pulsejet baghouse with Long Bag technology Mercury control systems / Activated carbon injection Sodium Bicarbonate, Trona and Hydrated lime injection systems Multi-pollutant High Rate Recirculation fluid bed scrubber systems Multi-clones Standard products
Bin vents Dust valves Material handling collectors

Primary Markets Served

Utility boilers Industrial / institutional boilers Biomass and Waste to Energy Cement and Lime Plants Steel (primary and secondary) Foundry Food Processing Chemical Processing Aluminum

Dustex In-House Capabilities

Engineering including Computational Fluid Dynamics modeling Fabrication Design/Build Project Management Controls and Automation Commissioning and Aftermarket Support

Dustex CFD Modeling

Dustex provides 3D flow modeling on critical areas to the scrubber, baghouse and ACI Injection systems 3D solid modeling and flow analysis is performed in-house Provides improved flow profiles in modules Improved Cleaning Performance Reduced potential for bag abrasion

Dustex Fabric Filters

Purpose of the Baghouse

The function of the baghouse is to collect the particulate waste from Process Gas Streams with a high level of efficiency The baghouse also provides enhanced mercury control with activated carbon injection prior to baghouse. Baghouse aids in HCl and SO2/SO3 control when coupled with a dry scrubber

Baghouse advantages over ESP

Capable of handling large temperature and volume swings. Higher level of mercury control with lower Carbon consumption on PAC systems. Capable of much lower emissions levels. Does not require pretreatment of gasses to control particulate. Generally speaking, baghouses have an overall lower total lifetime maintenance cost as compared to ESPs. ESPs have a reported high operational upkeep.

Fabric Filter Design Types

Reverse Air Filters

Reverse Air Design

Developed for with large volumes and large bags Air flows up through the inside of the bags where dust collects Cleaning is by a reverse air fan that pushes air backwards through the filter Limited to 2.25:1 gross A/C

Reverse Air Design

Designed as a panelized unit MUST clean offline Can be Cost effective at volumes Over 1,000,000 acfm (1,700,000 m3/hr) Formerly used in Utility industry, but largely replaced by pulse jet Still seen rarely in the Steel industry

Pulse Jet Baghouse Inlet Design Comparison

Hopper Entry vs. Housing Inlet Design, Cross-flow

Traditional Hopper Entry Design

Developed for use with short bags (< 18 feet) Air flow up through bags inhibits cleaning and leads to re-entrainment Can lead to abrasion problems and high pressure drop Used by some suppliers for long bag designs Limited to 4:1 A/C

Typical Hopper Entry Collector

Traditional Hopper Entry Ladder Baffle

Hopper Entry Advantages

The original Pulse Jet filter design Cost effective at volumes less than 300,000 acfm (500,000 m3/hr) Commonly supplied with walk in plenum Best design for low volumes where price is the most critical factor

New Technology
Housing Inlet Design, Cross-flow

Side Plenum Design

Single Modules with up to 304 bags Side Plenum ships loose Cost effective at volumes up to 500,000 acfm (850,000 m3/hr) Shop installed Hopper heaters and Insulation with cladding

Side Housing Inlet

New technology for long bag design >24 (7.3m) Flow enters side of module and flows across bags Efficient on-line cleaning at high A/C ratios Reduces bag abrasion issues

Side Plenum Module

Split Module Design

Single Modules with up to 576 bags Module ships as two halves with hoppers attached Cost effective at volumes in excess of 400,000 ACFM (680,000m3/hr) Single Train units up to 2,000,000 ACFM (3,400,000 m3/hr) Shop installed insulation and cladding Can be adapted to panelized design if required for large volume

Split Module Erection

Design Features

Dustex Top Door

Monolithic top door with integrated Cleaning System allows for easy bag access while avoiding confined space concerns Floating Pan design provides allows for module expansion without leaking Intermediate pressure pulse system provides efficient cleaning and long bag life.

Integral Top Door Bottom View Showing blow pipes

Header and Pulse Valve Assy.

Clean air plenum

30

Top of Tube Sheet

31

Bag Cleaning
On line vs. Off line

On-line Cleaning Operation

Flue stream to ID Fans

DP
Dirty Flue gas from upstream

33

On-line Cleaning Operation

Flue stream to ID Fans

DP
Dirty Flue gas from upstream

High DP condition detected

34

On-line Cleaning Operation

Flue stream to ID Fans

DP
Dirty Flue gas from upstream

Solenoid valve opens Cleans a row of filters While one row is being cleaned, the other rows in the module continue to operate
35

On-line Cleaning Operation

Flue stream to ID Fans

DP
Dirty Flue gas from upstream

Solenoid valve closes System starts another row of bags

36

Off-line Cleaning Operation

Flue stream to ID Fans

DP
Dirty Flue gas from upstream

37

Off-line Cleaning Operation

Flue stream to ID Fans

DP

Dirty Flue gas from upstream

High DP condition detected

Off-line Cleaning Operation

Flue stream to ID Fans

DP Dirty Flue gas from upstream

Stop flow in Module

Off-line Cleaning Operation

Flue stream to ID Fans

DP
Dirty Flue gas from upstream

Solenoid valve opens Clean a row of filters

40

Modern developments in Pulse Jet Baghouse Technology

CFD Modeling use as a progressive tool for distribution and inlet development Cross-Flow Inlet Design contrasted with older hopper entry
Cross flow development has allowed for:
more effective cleaning systems Significant reduction in high velocity streamlining and abrasion Elimination of can velocity Increase in Air to Cloth ratios (cloth face velocity) due to media effectiveness Increased filter life Aid in filter bag length increase

Additional Modern developments

Increase in filter bag length (as long as 10 meters) due to advancements an testing of cleaning systems in conjunction with cross flow technology
Development of long bag technology has allowed a very cost effective option to reverse air collector with smaller footprint Modern Long bag technology has allowed pulse collectors with the footprint equal to or smaller than Electrostatic Precipitators, with the added benefit of no emission swings with load swings

Module lift-off door sealing advancements reducing or eliminating air infiltration which causes corrosion and eliminates confined space issues that would be present n a walk-in plenum unit Filter media developments allowing wider range of applications and efficiency Control system advancements allowing:
Cost effective PLC based cleaning controls (without timer cards) Cost effective and reliable demand based cleaning which allows for tight baghouse DP control eliminating Furnace draft swings and helping retain sorbents on the filter media for maximizing HAP reduction particularly for Mercury control and dry scrubbing applications Easier plant wide networking and integration with DCS equipment as well as remote diagnostics options. PLC based redundancy availability

Dustex Fabrication
Dustex Fabrication Shop in NC Captive Shop in OH

Modularized Utility collector in Dustex Fab shop

Module Half On Jig

Erection Friendly Designs

Side Plenum and Split Module for More cost effective field erection

Side Plenum Erection

Erection Timeline (1 of 3)

Typical Baghouse Module

First Baghouse Module Being Lifted Into Place

First Baghouse Module Being Set In Place

First Six (6) Baghouse Modules Set In Place

Erection Timeline (2 of 3)

Final Six (6) Baghouse Modules Set In Place

Baghouse Inlet-Outlet Duct

Baghouse Top Section w/Installed Air Pipe

Baghouse Penthouse Steel

Erection Timeline

(3 of 3)

Baghouse Penthouse Structural Steel Erection

Baghouse Penthouse Structural Steel Erection

Baghouse Penthouse Level (Top of Baghouse El. 287-0)

Baghouse Dynegy Unit 2

Completed 110MW unit

Completed 300MW Unit

Nova Scotia Power

Activated Carbon Injection Systems (ACI)

Applicable Industries
Solid Fuel Boilers / Power Generation Minerals Processing / Cement Plants Municipal Solid Waste Combustion

Purpose of ACI
Introduce activated carbon into the flue stream to adsorb Mercury and Mercury compounds present in the flue gasses Activated Carbon Can Also be used for Dioxin/Furan control in MSW applications Carbon is injected through an array of injection lances to insure even distribution

Dustex ACI Scope

Dual Discharge Silo Pre-assembled Loss-inWeight feed system Injection lance supply including CFD model Standalone Control and Power Panel Skid Mounted

ACI systems

ACI Silo

Mercury Removal Test Data

1,058,000 ACFM operating at 375 deg F has tested at 90% mercury reduction with 0.58 #/million ACF injection rate 410,000 ACFM operating at 325 deg F has tested at 90% mercury reduction with 0.75 #/million ACF injection rate

Scrubbers for Removal of SOx and Acid Gases

Three Main Methods of Utility Size Scrubbers

Spray Dryer Advantages: Relatively Low Capital cost Easy for Retrofit applications with existing baghouse Simplicity Disadvantages: Not good for higher than 90% removal efficiencies Not good for Fuel Flexibility Lime slurry Equipment present Very High Maintenance

Three Main Methods of Utility size Scrubbers Lime Slurry reagent based Wet Scrubber Advantages: High Removal efficiency, greater than 90% Fuel flexibility Not size limited Disadvantages: Slurry Based High horsepower consumption More equipment hence associated maintenance

Three Main Methods of Utility size Scrubbers Circulating dry scrubber Advantages: Low Maintenance Simplicity High Removal efficiencies, greater than 90% Relatively Low Capital cost Fuel Flexibility Scrubbing efficiency higher than spray dryer, Well over 90% removal Lower operating temperatures with high reagent concentration allows adsorbsion of Heavy metals Disadvantages: Equipment elevation Requires Multiple trains for units over 300 MW

Dustex High Circulation Rate Dry Fluid Bed Scrubbers

HCl, SO2, HF Control Scrubbing efficiencies >90% Lower reagent consumption due to recirculation Lower Maintenance than Spray Dryer or Wet Scrubber Low operating temperature gives side benefit of Heavy Metals Control Utility projects over 50 MW executed in conjunction with Babcock Power

Operating Principal
Flue Gas Enters bottom of scrubber tower Fresh Reagent and recirculation from the fabric filter are added to create desired tower pressure drop Water Spray cools to 20-30 F above saturation Carry over material is collected in the fabric filter baghouse.

Scrubber Installation

110 MW Installation