ENVIRONMENTAL POLLUTION CONTROL

&

HEAT RECOVERY TECHNOLOGY

Fluidized Bed Technology:

− Scrubbers, Absorbers & Strippers

History:

− Developed & progressed by FTL & Osprey since 1991

− Nearly 500 scrubber and stripper plants installed

worldwide, extensively in Europe & N. America.

− 10 installations in Australia

− Blue Chip Clientele: BHP Billiton, Visy, Kronos etc.

GAS

LIQUID

3-Phase Turbulent

Flow

Ellipsoid Shape Skewers The C.O.G

Tumbling / Rotation Of Packing

Fluidized Bed Technology:

− Traditional Packed Towers & Sieve

Plates limited by their Available

Surface Area for Mass Transfer.

− Packed Towers Blockage from

solids or dust particles

increases in DP & diminished

efficiency.

− TURBOIDS/TURBOPAK® fluidised

by the ascending gas stream

− Highly turbulent mixing & liquid

shearing

REVOLUTIONARY PACKING

− Patented FTL/Osprey Turboid® & Turbopak ®

− Traditional Sphere Shaped Packing Proved Unstable

(Swirl Effect / Sideways Movement)

− Other Issues Included Channelling Of Gas, Poor

Distribution of The Bed & Unreliable Performance

− Patented Ellipsoidal & Ovoidal Shapes Overcame

These Issues

− More Energy Efficient To Fluidize

− Indent Adds Extra Thrust To The Tumbling Motion

− Skewed C.O.G of the media causes them to oscillate

TurboPak® Ovoid with Concave

Indentation

Tumbling & Intense Violent Mixing

Gas Flow

Unsurpassed Mass & Heat Transfer

− Turbulence creates very high Reynold’s Number High Mass &

Heat Transfer Coefficients

− Intimate “Mixing” Provides Fast Contact-Driven Mass Transfer /

Absorption

Equipment Size Reduction

− Reduced Equipment Height/Footprint compared to equivalent

packed/sieve-plate tower

Guaranteed Blockage-Free Operation

− Bed remains 100% blockage-free even using slurries, biomass &

precipitating systems

− Flooding is Impossible - L/G Range = 0.1 L/m3 - No Upper Limit

Multi-use Functionality

− Simultaneous Absorption, Particulate Removal & Heat Recovery in One

− More Energy Efficient Than a Venturi / Packed Tower Combination for

the Same Performance

Operating Characteristics: Mass & Heat Transfer Rates

− Overall Gas Mass Transfer Coefficient (of Species A), KOG,A Is A Function Of Many Things,

One Of Which Is The Pressure Gradient dP/dh

− The Pressure Gradient Is A Function Of L/G, y (Shape Factor), f (Accentric Factor), S

(Shape Factor), r (Gas Density).

− Using Ellipsoidal Packing Effects Both y and f (=1.0 For Spheres)

− Varying The Size And Shape Of The Element One Can Control The System dP/dh & \

Regulate The Mass, Heat Or Particulate Transfer Efficiency

− Another Key Factor Is The “Surface Renewal Rate” - The Rate At Which Fluid Elements At

The Phase Interface Are Being Replace By Fresh Elements From The Bulk

− Simply By Increasing Pressure Gradient Will Not Produce Optimum Design Conditions…

− The Absolute Value Of The Mass & Heat Transfer Coefficients Is In Reality A Function Of Bed

Turbulence, Surface Renewal Rates S, And Diffusivity D – all of which are very poor for

traditional Spherical Balls. Thus Produce Much Lower Mass Transfer Rates

− Using Ellipsoidal Shapes, Bed And Tower Heights Can Be Reduced for Fixed Beds.

Unsurpassed Mass & Heat

Transfer

− Conventional fixed packing systems

are extremely limited in their mass &

heat transfer performance due to the

complicated laminar flow patterns

around packing shapes

− In the TS system these flow patterns

are broken down to decrease mass

transfer resistance & improve

gas/liquid mixing

SYSTEM OPERATING

DETAILS

TURBOSCRUBBER VENTURI/PACKED

TOWER

LIQUID MEDIUM SEAWATER OR

35% W/W KCI

SLURRIES

SEAWATER ONLY

SO2 REMOVAL 99.80% 99.80%

KCI/C PARTICULATE

REMOVAL @ 1.7

MICRON

99% 99%

PRESSURE DROP 6.4" W.G. 15" W.G.

RELATIVE VOLUME

(APPROX)

1 5

PLUGGING/CLOGGING NO YES

SLURRY HEAT

RECOVERY RATE

4.2MW NONE POSSIBLE

A Real Case Comparison of Equivalent Efficiency Systems

TOWER TYPE TURBOSCRUBBER FIXED PACK

PACKING TURBOID TYPICAL 2" RING

H2S REMOVAL 99.997 99.997

TYPICAL DIAMETER 1.25 METER 1.75 METER

ABSORBTION ZONE

HEIGHT 2 METERS 7 METERS (FIXED)

PRESSURE DROP

(APPROX) 6" W.G 6" W.G

A Real Case Comparison of Equivalent Efficiency Systems

Typical F.G.D. Heat Recovery/Pollution Control System Using Turboid Technology

Cut Costs & Emissions with a Non Foul High Efficiency Turbulent Bed:

− Dramatically Improve Underperforming Or Plugged Up Scrubber

− Technical Support & Pilot Trials Available

− Radically Improve Absorption Rates

− Low Height Maintenance Free Beds

− Submicron Particulate Removal

− Low DP Turbopak® /Turboid® Packing

− No Major Retrofit Modifications

− Just Replace Grids & Packing

− Maintain Recycle Pipework & Fan

− Guaranteed Non Plugging Beds

Engelhard, Metal Recovery, U.K.

Hercules BetzDearborn, Chemicals, U .K.

SPP/Suncor , Oil Recovery, Australia

Bartz, Metal Castings, Germany

MASS

TRANSFER

PARTICLE

TRANSFER

HEAT

TRANSFER

FLUID

DYNAMICS

TOWER

DESIGN

GAS

ABSORBED SO2 PARTICULATES

KCI salt

crystals and

fine carbon

(soot)

INLET GAS

TEMP. 174ºC

GAS FLOW-

RATE

50,000

m³/hr

COLUMN

DIA. 2.3m

LIQUID

MEDIUM

KCI / NaCI

Slurry or

Seawater

MEAN PARTICLE

SIZE 2.5 micron

% APPROACH

TEMP. 87%

OPERATING

MODE

Once

Throu'

OVERALL

HEIGHT 8.5m

INLET CONC. 300 ppm % REMOVAL 99%

HEAT

TRANSFER

RATE

4.1 MW PRESSURE

DROP 1600 Pa MOC

Mild

Steel,

Glass

flake

Coated

% ABSORBED 99.8%

TurboScrubber ® Unit Simultaneously:

− Scrubs fine KCl salt & soot particles

− Absorbs SO2 Gas, and

− Recovers over 4 MW of heat energy

MASS

TRANSFER

PARTICLE

TRANSFER

HEAT

TRANSFER

FLUID

DYNAMICS

TOWER

DESIGN

Gas

Absorbed HF Particulates Al2O3

Inlet Gas

Temp. 80ºC

Gas Flow-

Rate

260,000

Am³/hr

Colunm

Dim. 7m x 4m

Liquid

Medium

Water/Alkali

ne Solution

Mean Particle

Size 1.7 micron

% Aproach

Temp. 93%

Operating

Mode

Recycle/

Bleed

Overall

Height 30m

Inlet Conc. 50ppm % Removal 85%

Heat

Transfer

Rate

3600 kW Pressure

Drop 800 Pa MOC

Plastic

lined steel

% Absorbed 99%

− 6 large TS units - combined flow of 1.5 x106Am3/hr

− Considerably Cheaper Option than Bag Filters

− Simultaneously Remove:

Fine PM, Combustion Products & HF Gas

MASS

TRANSFER

PARTICLE

TRANSFER

HEAT

TRANSFER

FLUID

DYNAMICS

TOWER

DESIGN

Gas

Absorbed SO2 Particulates Na2 S2 O5

Inlet Gas

Temp. 60ºC

Gas

Flowrate

7000-

17000

m³/hr

Column

Dia. 1.15m

Liquid

Medium NaOH

Mean Particle

Size 1 micron

% Approach

Temp. 96%

Operating

Mode Recycle

Overall

Height 7.2m

Inlet Conc. 2000ppm % Removal 98%

Heat

Transfer

Rate

50 kW

(reaction)

Pressure

Drop

up to

3000 Pa MOC

PP, GRP

reinforced

% Absorbed 99.9%

− Simultaneously Scrubs Fine Sodium Metabisulfite Dust

And SO2 Gas, From Dryers, To High Efficiencies.

− Replacement And Upgrade For An Existing Packed

Scrubber (Prone To Blockage By The Precipitated

Solids)

MASS

TRANSFER

PARTICLE

TRANSFER

HEAT

TRANSFER

FLUID

DYNAMICS

TOWER

DESIGN

Gas

Absorbed SO2 Particulates

Fine Carbon

(soot) from

oil firing

Inlet Gas

Temp. 135ºC

Gas

Flowrate

41,000-

82,000

m³/hr

Column

Dia. 2.35m

Liquid

Medium

Process

Effluent

Mean Particle

Size 2 micron

% Approach

Temp. 98%

Operating

Mode

Recycle

with

variable

bleed &

make-up

Overall

Height 9.8m

Inlet Conc. 800ppm % Removal 97%

Heat

Transfer

Rate

400 kW

(typical)(4

MW

potential)

Pressure

Drop

1000 Pa

(typical) MOC

Mild Steel

Glass

Flake

coated

Outlet Conc.

Controlled

at 150 ppm

(typical)

− Simultaneously Scrubs Fine Soot, Absorbs SO2 Gas, &

Recovers Waste Heat.

− Uses Effluent Buffer Solution as the Scrubbing Medium

− Unique Non-clogging Feature Ensures Reliable &

Consistent Operation Without Increase in Gas Side DP

− NOx Scrubbing Systems - Operated With NaOH Or

Powerful Oxidant (H2O2).

− TS’s High Mass Transfer Performance Compact

Towers Minimise Space & CAPEX.

− Existing NOx Scrubbers Easily Retrofitted

− Tower to Right (N. France) retrofitted from fixed bed

(Pall rings)

Breakthrough Air Stripping Technology

− 100% Non-Clogging Water Clean-up Technology

− Low Profile Units Available

− Small Footprint

− Low Energy Consumption

− Easily adaptable for Off-Gas Treatment

− High Removal Rates of VOC's, Semi-Volatiles and Napthalenes

Over 200 Units Installed Worldwide

− CO2 Capture From Flue Gas

− Pyrolysis / Gasification Syngas Clean Up

− Pulp / Paper Industry Heat Recovery

− Acid Gas & Particulate Removal In Metal

Processing

− Incinerator Off Gas Treatment

− Hydrogen Sulphide Removal From Gas

Streams With Significant CO2 Conc.

− Etc Etc…..