Hurricane HR System to Reduce Particulate Matter Emissions from a Dan Power 100t/h high pressure water-tube steam boiler under 130mg/Nm3

FOREWORD

ACS supplied a dedusting equipment for boiler manufacturer Dan Power who integrates the equipment in the boiler package, for end customer FS Bioenergia. Dan Power was founded in April 2001 as an engineering company specialized in energy recovery boilers for cogeneration plants using turbines or gas engines, steam equipment for sulfuric plants and water-tube oil and gas boilers. Some operations were partly transferred from Thermocal, a sister company in operation since 1996 and where bagasse boiler projects were later concentrated. From 2013 Danpower expands its product line with the launch of oil and gas fired-tube boilers within the most up-to-date technology concepts, as well as partnering with Finnish company for circulating fluidized bed boilers. DanPower’s operating philosophy is to be a midsize, hightech company, agile in its decisions, to promptly meet the needs of its customers, with a vast technological background. End client FS Bioenergia is a company focused on corn-based ethanol production and expected to become one of the three largest ethanol manufacturers in Brazil with a capacity of 2,6 billion liter per year. Steam generated by Dan Power’s boiler is essential for FS Bioenergy’s process.

IDENTIFYING THE PROBLEM AND SOLUTION

FS BIOENERGIA plant located in Lucas do Rio Verde, Matogrosso state, is the first industrial facility using 100% corn for ethanol production in Brazil. To produce steam, the plant operates a Dan Power 100t/h high pressure water-tube steam boiler which burns forestry residues mainly of eucalyptus wood and rice husk. ACS’ challenge was to reduce particle emissions from an inlet concentration of 600mg/Nm3 dry at 8% O2 (after Multicyclone preseparator) to less than 130mg/Nm3 dry at 8% O2, thus exempting the use of a bag filter and the associated problems and operating costs (changing of filter elements and related downtime costs, costs with compressed air, etc.). After confirming the particle size distribution (see Fig.2) and other relevant operating conditions , ACS designed a system composed of 40 Hurricane HR type cyclones , arranged in 10 batteries of 4 cyclones each, operating in parallel and distributed over 5 lines. The results achieved were within the expected values (100mgNm3 dryy at 8% O2).