Introduction and Challenges
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1 Introduction and Challenges
2 Introduction Applicability of MS1723 method Methodology Simultaneous isokinetic sampling at inlet & outlet Dust analysis (gravimetric for weight and laser diffraction for PSD analysis) Calculation formulas Sample results table and graphs Challenges in sampling Factors resulting to inconclusive results Ways to improve accuracy
3 Applicability of MS1723 Performance evaluation for mechanical dust collector defined as a device which separates dust in a dry state from gas through the application of inertial and gravitational forces only E.g. settling chamber, cyclones Valid for confined flow system No leakage along ducting
4 Simultaneous isokinetic sampling at both inlet and outlet of dust collector Using MS1596:2003 method, measure particulate concentrations Consists of two teams (1 at inlet, 1 at outlet) A coordinator needed (coordinate both teams, log plant conditions) Samples collected to be analyzed at accredited laboratory Mass determination (gravimetric)
5 Collected samples further analysed for particle size distribution (PSD) Using ISO method (particle size analysis laser diffraction method) Analyze at least 64 intervals of particle sizes Size range to be analyzed between 0.1 to 200 micron, analysis shall always correspond to sizes present in flue gas
6 Collection of dust must be simultaneous - at same time both inlet and outlet Minimum of 3 tests 2 conclusive tests required
7 Preparation before sampling Choose the most suitable inlet & outlet sampling points Coordinator must choose suitable location Can see both isokinetic teams If not possible, use 2-way radios (walkie talkie)
8 Testing procedure Follow MS1596 method Coordinator to control the sampling times for both inlet and outlet teams. Must be at the same time Process conditions to be recorded plant capacities, type of fuel, excess air, temp, pressure, etc. Repeat tests 3 times
9 Efficiency of dust collector: where c in : dust concentration before dust collector c out : dust concentration after dust collector
10 Relative outlet PSD (in terms of inlet PSD): where m i,out : mass particle size interval after dust collector Note: All particle size distribution (m i,in and m i,out shall be normalized to 100)
11 Grade efficiency: where m i,in : mass particle size interval before dust collector
12 Source: Boiler in POM, fuel=palm shell & fiber Type of dust collector : Multicyclone duct: rectangle, 2.10x0.84m A=1.76 m2 Test Sampling time Static P Temp. Water cont. O2 cont. CO2 cont. Velocity Flowrate Dust conc. Time (hrs) # minutes "H20 o C % % % m/s Nm3/hr g/nm Outlet duct: circular, dia=0.9m A=0.64 m2 Outlet Test Sampling time Static P Temp. Water cont. O2 cont. CO2 cont. Velocity Flowrate Dust conc. Time (hrs) # minutes "H20 o C % % % m/s Nm3/hr g/nm
13 Test 1 Test 1 Test 2 Test 2 Test 3 Test 3 Average Average Outlet Outlet Outlet Outlet Dust concentration (g/m 3 N) Efficiency (mass basis) Note : Dust concentration in dry basis, at STP, expressed at 12.0% CO2
14 Size under (um) Particle Size Distribution Test 1 Test 2 Test 3 Particle Size Distribution Test 1 Test 2 Test 3 Avg Outlet Outlet Outlet (%) (%) Avg Size under (um) Particle Size Distribution Particle Size Distribution Test 1 Test 2 Test 3 Test 1 Test 2 Test 3 Avg Avg Outlet Outlet Outlet (%) (%)
15 Particle Size Distribution Particle Size Distribution Test 1 Test 2 Test 3 Test 1 Test 2 Test 3 Size Avg Avg under (um) Outlet Outlet Outlet (%) (%) Size under (um) Particle Size Distribution Test 1 Test 2 Test 3 Particle Size Distribution Test 1 Test 2 Test 3 Avg Outlet Outlet Outlet (%) (%) TOTAL Avg
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19 Size under (um) (%) TEST 1 TEST 2 TEST 3 Outle t relati ve Effici ency partic le size (%) Outl et relat ive Effici ency partic le size (%) Outle t relati ve Effici ency partic le size na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na Size under (um) (%) TEST 1 TEST 2 TEST 3 Outle t relati ve Effici ency partic le size (%) Outl et relat ive Effici ency partic le size (%) Outle t relati ve Effici ency partic le size na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na
20 Size under (um) TEST 1 TEST 2 TEST 3 (%) Efficie ncy Outlet relativ e particl e size (%) Efficie Outle t relati ve ncy particl e size (%) Efficie ncy Outlet relativ e particl e size na na na na na na Size under (um) (%) TEST 1 TEST 2 TEST 3 Outlet relativ e Efficie ncy partic le size (%) Outl et relati ve Efficie ncy partic le size (%) Outlet relativ e Efficie ncy partic le size
21 Test is conclusive if: Highest difference between grade efficiencies is <20% Average difference is <10% Efficiencies measured may be exempted, if PSD <2% of total mass on inlet
22 Sizes below micron can be exempted, due to <2% of total mass on inlet Size under (um) (%) TEST 1 TEST 2 TEST 3 Outle t relati ve Effici ency partic le size (%) Outl et relat ive Effici ency partic le size (%) Outle t relati ve Effici ency partic le size na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na Size under (um) (%) TEST 1 TEST 2 TEST 3 Outle t relati ve Effici ency partic le size (%) Outl et relat ive Effici ency partic le size (%) Outle t relati ve Effici ency partic le size na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na na
23 Sizes below micron can be exempted, due to <2% of total mass on inlet Size under (um) TEST 1 TEST 2 TEST 3 (%) Efficie ncy Outlet relativ e particl e size (%) Efficie Outle t relati ve ncy particl e size (%) Efficie ncy Outlet relativ e particl e size na na na na na na Size under (um) (%) TEST 1 TEST 2 TEST 3 Outlet relativ e Efficie ncy partic le size (%) Outl et relati ve Efficie ncy partic le size (%) Outlet relativ e Efficie ncy partic le size
24 Accuracy test for full range and ranged onwards: Test Test Test Accepted Criteria max diff (Full range) <20% avg diff (Full range) <10% max diff ( onwards) <20% avg diff ( onwards) <10% Test 2 and 3 conclusive for size range micron onwards. Test 1 and 3 conclusive for size range micron onwards. Test 1 and 2 not conclusive (size onwards) Max. Grade efficiency Diff Test Test Test Average Test Test Test Size under (um) Test
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26 Isokinetic sampling ratio Isokinetic ratio not within % are not acceptable; test should be repeated Sampling not simultaneous Site conditions could make coordination difficult No visual/audible cues between the two teams (inlet and outlet) due to obstacles, distance, noise If sampling temporarily stopped by one team, the other team may not be aware
27 Poor handling of dust samples Esp. during transferring of dust laden filter into sealed container after finish sampling. Fine particles could be loss due to spill; affecting gravimetric and particle size analysis
28 Poor siting of sampling point Either at both inlet or/and outlet Porthole too close to disturbances MS1596 requires minimum 5 diameters from disturbance Flow not steady state (turbulence)
29 Impro design of dust collector Dust collector not appropriately sized according to emission conditions (P, T, gas compositions, flowrate, moisture content)
30 Mismatch of oating and design capacity Source emitting more than what dust collector is designed to accept Too high dust load due Higher moisture content
31 Non-steady state condition during sampling Source combustion not steady Varying velocity and gas density in chimney/ducting, affecting accuracy of MS1596 isokinetic sampling
32 Insufficient dust samples Not enough amount to determine particle size distribution via laser diffraction Dust loss from poor handling of filter/thimble
33 Prior arrangement with site oator Inform earlier on actual sampling date/time Site oator can plan ahead source emission conditions for testing Oation must be steady state Minimize unplanned oating conditions Sudden fuel type change Sudden increase/decrease in load to prevent plant upset, etc.
34 Competent isokinetic sampling teams Important to maintain the % isokinetic centage ratio Careful handling of thimble/filter after sampling (to avoid spill/loss) Competent coordinator Requires 1 son (not the test sampling team member) Skillfully coordinate both inlet and outlet team sometime need to improvise accordingly to overcome site conditions (heat, noise, weather, barriers) Can record real time flue gas data without need to disrupt isokinetic teams
35 Competent designer Reputable contractor to design the dust collector to fit the actual oating conditions Not copy paste design based on principal manufacturer template Make sure the sampling porthole location suitable (minimum 5d from disturbance) Awareness of MS1596 requirement is vital Plant engineer must give useful data Wrong data given mismatch of oating & design para. Competent APCS sonnel Regular monitoring of dust collector formance Record pressure drop, inspect discharge hop, fan motor amage, check for corrosion & leakage
36 Muhamad Khairul Najib bin Ahmad
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