Pollution Engineering January 2012

POLLUTION CONTROL SOLUTIONS SOLU FOR AIR, WATER, SOLID & HAZARDOUS WASTE WAST

JANUARY 2012

2012 10 Top Techs Pg 17 RO Applications Pg 23 Chelated Metals Removal Pg 27 www.pollutionengineering.com

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INSIDE 17

JANUARY 2012

VOLUME 44

NO. 1

FEATURES Advanced Air Pollution Control in One System . . . . . . . . . . . . . . . . . . . . .

12

Unlike other filter systems, advanced, low-density ceramic filter systems are now capable of removing particulate matter (PM), NOX, SO2, HCl, dioxins and mercury, all within a single system.

23

2012 Ten Top Technologies . . . . . . . . . . .

17

Pollution Engineering takes a sneak peek into future technologies that could impact the environmental industry.

Reverse Osmosis Membrane Processing – Applications Insights. . . . . 23 How can reverse osmosis technology be applied to wastewater and process water to maximize efficiency?

Treating Citrate Chelated Metals . . . . . . 27

27

As many scientists and engineers have discovered in recent years, the treatment of citrate-chelated metals may not be as complicated as some researchers originally believed.

COLUMNS The Editor’s Desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 Sometimes, politicians seem to try to get in the way of progress and cause more harm than good. Such is the case in energy management. By Roy Bigham Legal Lookout . . . . . . . . . . . . . . . . . . . . . . . . .32 . 10

Due to concerns with former regulations, the DTSC has recently offered more effective regulations to improve the safety of California’s consumer products in 2012. By Lynn L. Bergeson

Air Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 The reporting period for the EPA’s Greenhouse Gas Reporting Program will last from Jan. 1 to Dec. 31, 2012. The reporting deadline is currently March 31. By Erin Manitou-Alvarez and Alex Chamberlain

DEPARTMENTS EnviroNews . . . . . . . . . . . . . . . . . . . . . . . . . 08 PE Events . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 Air Emission Control Products . . . . . . . . . . 11 Flow & Level Monitoring Equipment . . . . 11 Classified Marketplace . . . . . . . . . . . . . . . 38 Advertisers Index . . . . . . . . . . . . . . . . . . . . 41

State Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Environmental Rules change daily. BLR brings a few of the latest changes needed to stay in compliance. By BLR

Cover caption: Special graphics supplied by the Tri-Mer Corporation.

SPECIAL REPORT Technical Profiles . . . . . . . . . . . . . . . 29

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Keep up with changing industry news with Pollution Engineering's This Just In section.

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Greenhouse gas Emissions Forge Higher Representatives meeting in Durbin are learning that emissions continue to accelerate. The reasons given this time might be a surprise.

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Pollution Engineering JANUARY2012

the

ALERT

EDITOR'SDESK When Politics Create Pollution Sometimes, politicians seem to try to get in the way of progress and cause more harm than good. Such is the case in energy management.

F

or the most part, people agree that nuclear energy production is more earth-friendly than burning coal. The handling of nuclear waste products is a hassle for everyone involved. There had been a plan to bury the wastes under a mountain. Huge sums of money were invested in developing a suitable site, engineering the systems and writing unique environmental regulations that would have to be in place for one million years. Of note, as hard as it may be to believe, that is not a typo and it is not an exaggeration. In the end, however, a few politicians and special interest groups successfully derailed the project known as the Yucca Mountain Nuclear Waste Depository. According to the U.S. Nuclear Regulatory Commission, there are presently 104 commercial reactors located throughout the United States. Uranium is the most common fuel that is used at these facilities. Manufacturing nuclear rods is a long, expensive process. Nonetheless, the military still uses some of the processed materials for their atomic bombs. Of course, all of these facilities, as well as some of the bombs, produce wastes at the end of their lifecycles. Unfortunately no acceptable methods have been developed for long-term disposal of such wastes. Undoubtedly, the nation needs to produce more energy to meet future requirements. It does not need to make more waste with no disposal plans though. Despite the fact that President Obama has ordered the decommissioning of some of the country’s bomb inventory, the military does not want to allow nuclear facilities to be shut down. Politicians constantly fight against placing wastes in their own states, yet they too do not want to shut down the nuclear energy plants that are powered by uranium.

There is a solution The uranium isotope that is used remains deadly for more than one million years. Wastes from these reactors will have to be monitored for that period of time, unless science can find a way to decommission the fissile material. It is important to note that uranium does not have to be the only fuel that is used in nuclear reactors. Enter thorium. This material has been known for many years as a material that can be used to drive nuclear power producing plants. It is highly abundant, with heavy concentrations in Australia, India

and the United States, and is three times as abundant as uranium. Not only is it easier and safer to process, but the waste materials only remain deadly for hundreds of years, rather than millions.

What is holding up the conversion? In the 1950s and 60s, researchers at Oak Ridge National Laboratory worked to develop reactors that used thorium. However, much of the work was abandoned after tests conducted by the military concluded that they were able to adapt uranium power for their navel fleets. Further work with thorium was heavily curtailed.

“

…nuclear energy production is more earth-friendly than the burning coal.

It was also noted by the researchers that thorium could not be used to manufacture nuclear weapons. Still, as the nation’s political and military climate was quite uncertain at the time, the United States needed to continue to build and develop nuclear weapons.

”

A change in the wind Lately, China and Russia have announced that thorium nuclear power systems are currently being developed to meet their future energy needs. But, the two countries have encountered the same problems that the United States is facing – there is no place to put the wastes. In addition, while our nation had an issue with the Three Mile Island nuclear facility, the United States’ problems have paled in comparison to Russia’s Chernobyl and Japan’s Fukushima Daiichi disasters. Maybe we should consider handing over all of our centrifuges to the military and refitting our nuclear power reactors – and then tell our politicians to stay out of it. PE

Roy Bigham is Editor of Pollution Engineering. He can be contacted at [email protected]

JANUARY2012

www.pollutionengineering.com

7

ENVIRONEWS PE Events JANUARY 2012 30-1

15th Annual EUEC, Phoenix Convention Center, Phoenix, www.euec.com

FEBRUARY 2012 9-11

Everything About Water, India Expo Centre, Delhi, India, www.eawater.com

14-17 RCRA Compliance Workshop, San

Antonio, www.epaalliance.com/rcraworkshopsanantonio12.html

MARCH 2012 6-9

WQA Aquatech 2012 USA, Las Vegas Convention Center, Las Vegas, www.wqa.org

11-15 Pittcon Conference and Expo 2012,

Orlando, Fla., www.pittcon.org 13-15 Water, Energy, Technology and

Environment Exhibition 2012, Dubai, United Arab Emirates, www.wetex.ae

14-16 Environmental Industry Summit, San

Diego, www.ebionline.org/environmental-industry-summit

19-23 8th International Conference on Air

Quality - Science Application, Athens, Greece, www.airqualityconference.org

27-29 7th AsiaWater 2012 Expo & Forum,

Kuala Lumpur, Malaysia,

www.asiawater.merebo.com

APRIL 2012 16-20 11th World Filtration Congress, Graz,

Austria, www.wfc11.at 18-20 The Carolinas Air Pollution Control

Association Spring Meeting, Asheville, N.C., www.capca-carolinas.org

MAY 2012 7-11

IFAT 2012, the 17th International Trade Fair for Water, Sewage, Refuse and Recycling, Munich, Germany, www.ifat.de/en/Home

21-23 Global Conference on Oceans, Climate

EPA Enforcement Actions Reduce Pollution The EPA has released its yearly enforcement and compliance results. The agency reported that FY2011 actions eliminated more than 1.8 million pounds of pollution, including 300 million pounds in the Great Lakes region alone. As examples of action within Region 5, the EPA and the Department of Justice reached a settlement with the Northeast Ohio Regional Sewer District for Clean Water Act violations. The settlement will keep untreated sewage out of Cleveland-area waterways and Lake Erie. The agency also settled with Northern Indiana Public Service Co. to install state-of-the-art air pollution control technology at four coal-fired power plants, which will eliminate more than 68,000 tons of harmful emissions. In a final example, Honeywell International Inc. pleaded guilty to hazardous waste storage violations and was ordered to pay a criminal fine of $11.8 million. More information on enforcement and compliance activities is available at www.epa. gov/compliance/resources/reports/endofyear/eoy2011/index.html.

Mercury is a Hot Topic The final Mercury and Air Toxics Rule was expected to be published in December 2011. Individual states have been taking action on mercury emissions for quite some time but, when the federal rule is released, industry watchers, such as the Robert McIlvaine Company, are expecting the market to greatly impact air pollution control suppliers. Treating mercury sources from water has been the biggest market, with activated carbon suppliers providing 500 million pounds of product each year. Activated carbon that is used to treat mercury in air emissions has grown to roughly 50 million pounds per year; such usage has grown sharply over the past two years. However, when the federal mercury control rule is finalized, it is expected that carbon use, as a result of this single rule, will result in about a $1 billion per year market to treat coal-fired power plant air emissions. Coal is the fuel of choice for power plants that currently supply about 45 percent of the nation’s energy needs and, so far, it appears carbon is the most cost-effective control.

and Security, Boston, www.gcocs.org 21-24 Remediation of Chlorinated and

Recalcitrant Compounds, Monterey, Calif., www.battelle.org/conferences/

CORRECTION

chlorinated/index.aspxww.euec.com

I want to take time to thank all of those that pointed out to me that the world’s population passed seven billion rather than the seven million that I mentioned in my editor’s comment column in December. I would like to say that I was just testing to see how many really read my pieces but such was not the case. I merely typed the wrong letter and it was indeed noted by many readers of the column, Thank you and please keep the feedback coming.

JUNE 2012 3-6

Windpower 2012 Conference and Exhibition, Atlanta, www.awea.org/events

10-14 AWWA Annual Conference and

Exposition 2012, Dallas, www.awwa. org/ace12

Visit the Calendar of Events at www.pollutionengineering.com for additional information. 8

Pollution Engineering JANUARY2012

PERFORMANCE THROUGH ENGINEERING Free brochure on BETE FGD Absorber nozzles For Flue Gas Desulphurization BETE’s FGD absorber nozzles are guaranteed to function over prolonged periods and in harsh conditions. Nozzles have been designed to accommodate high-flow rates, while minimizing pressure requirements and maintaining excellent atomization.

Drop-in Spray Lances from BETE Custom spray lances, quills, and injectors BETE provides drop-in solutions in the form of custom spray lances, quills, and injectors. Why endure the time and hassle to source pipe, flanges, nozzles, and fittings separately and then coordinate fabrication and testing of the assembly when you can have BETE do it all for you?

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The XA Nozzle System from BETE is ideal for injection and selective catalytic reduction Produces a no-drip or high-speed spray shut-off BETE’s low flow, air atomizing XA series nozzles provide very low flow rates. They are available in eight different spray patterns and numerous flow rates. The XA nozzles can be supplied with a number of hardware options to allow cleanout, shutoff of both. Hardware options are available in manual and pneumatic versions.

Washing BETEʼs NEW Low-Flow MaxiPass Nozzle Clog-free design with maximum free passage The easy to install MPL series nozzle, with its clog-resistant design, easily handles dirty, contaminated liquids. This energy efficient, low flow, full cone nozzle is highly reliable under the most difficult conditions. BETE’s MaxiPass gas scrubbing nozzle

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LEGALLOOKOUT By Lynn L. Bergeson

California’s New Safer Consumer Products Regulations Due to concerns with former regulations, the DTSC has recently offered more effective regulations to improve the safety of California’s consumer products in 2012. n Oct. 31, 2011, the California Department of Toxic Substances Control (DTSC) released an informal draft of their Safer Consumer Products Regulations (SCPR). The proposal came after the California Secretary for Environmental Protection instructed DTSC to stop issuing proposed regulations and to instead “take additional time to be responsive to the concerns raised and revisit the proposed regulations.”

O

Background

Discussion

Concerns raised with the earlier regulation included the proposed exemption of certain chemicals; the decision to focus on children’s, personal care, and household cleaning products during the first five years; and the process by which chemicals of concern (COC) and priority products (PP) were identified and alternative assessments (AA) were conducted. In the revised regulations, DTSC has removed exemptions for unintentionally added chemicals, as well as chemicals for which there is “no exposure pathway.” The DTSC has also eliminated the initial focus for certain types of products, and has expanded the criteria and processes by which COCs and PPs are identified and prioritized and AAs are conducted.

The availability of the regulations provides a useful snapshot of the Green Ribbon Science Panel’s thinking after months of deliberations. Unfortunately, the informal draft regulation is quite cumbersome with its many definitions, criteria and procedures. Companies with consumer products in the commerce stream in California will need to notify DTSC that their products are PPs (or cease to enter the product in the stream of commerce in California or satisfy a de minimis exemption); that they can perform an AA and prepare a Preliminary AA Report and Final AA Report; and that they are able to comply with any regulatory responses that are applicable to their products or that DTSC determines are necessary. Companies also may need to respond to information requests from DTSC, substantiate claims when information is submitted as a trade secret and potentially utilize the dispute resolution procedures to dispute certain actions taken by DTSC. DTSC said that these responsibilities may be fulfilled by a consortium, trade association or similar organization. Yet, within the regulations, DTSC does not mention conditions or criteria regarding the methods in which issues (e.g., formation, compensation) will be resolved. The regulations are currently available at www. dtsc.ca.gov/LawsRegsPolicies/Regs/upload/SCPRegulations-Informal-Draft-10312011.pdf. PE

Stages of regulation The informal draft regulations anticipate implementing the core provisions of the program in four stages, as follows: • DTSC to establish a chemCOC list: Th DTSC will first establish a COC List within 30 days after the effective date of the regulations. DTSC said that the list will include approximately 3,000 chemicals, which are defined in Section 69502.2(a) as substances that exhibits a hazard trait or environmental or toxicological endpoints as identified by the Office of Environmental Health Hazard Assessment pursuant to Health and Safety Code Section 25256.1 and meets one or more of certain criteria. • DTSC to develop a PP list: DTSC will evaluate and prioritize products that contain COCs to develop a list of PPs for which AAs must be conducted. • Companies must identify their PPs and conduct AAs if not exempt: DTSC will require “responsible entities” – including manufacturers, importers and retailers who sell products in California – to notify DTSC within 60 days of a PP’s listing that its prod-

10

uct does or does not qualify for an exemption. • DTSC will identify and impose regulatory responses on PPs/COCs: Once a Final AA Report is submitted and DTSC determines it is compliant (i.e., not deficient), the department will specify a proposed due date for implementation of the regulatory response after considering the complexity of implementing such a response.

Pollution Engineering JANUARY2012

Lynn L. Bergeson is managing director of Bergeson & Campbell, P.C., a Washington, D.C., law firm focusing on conventional and engineered nanoscale chemical, pesticide, and other specialty chemical product approval and regulation, environmental health and safety law, chemical product litigation, and associated business issues, and President of The Acta Group L.L.C. and The Acta Group EU Ltd. with offices in Washington, D.C., and Manchester, U.K.

PEPRODUCTS Product Focus: Air Emission Control Leak Locators

Pleated Filter Elements

The company’s B-PAC series of Baghouse Performance Analyzers and Controllers have been designed to incorporate control, sensing, and signal analysis, and save dust collector operators time and money. To help operators reduce their working hours and operating costs, the analyzers and controllers can detect filter leaks well before emissions are noticeable and find failed pulse solenoids, which may ultimately plug filters.

In order to improve the performance of its SimPleat filters, the company has designed new filter elements that can be specifically used for industrial air filtration. As a result, by utilizing SimPleat filters, customers can now own a more durable product as each of the filter elements can be u s e d in applications of up to 180° F. The filters can be used in various applications, including mixers and nuisance-dust control systems.

FilterSense Beverly, Mass. • (978) 927-4304 www.filtersense.com

General Electric

Environmental Control Booth To protect workers from dust and noise generated in plant areas, the Tri-Flow Environmental Control Booth has now been released to the general public. The booths offer purchasers proficient filter performance, as they operate at a lower pressure drop than other cartridge filters, leading to a longer filter life. The booths also have a ledge-free interior that minimizes dust accumulation, which is valuable for individuals who weld or sand.

Tri-Mer Corporation

Fairfield, Conn. • (203) 373-2211 www.ge.com

Owosso, Mich. • (989) 723-7838 www.tri-mer.com

Product Focus: Flow and Level Monitoring Ultrasonic Flow Measurement/Logging Systems The company’s recently developed ultrasonic flow measurement/logging systems are available in two portable models, the Portaflow 220 and 330, as well as two fixed i n s ta l l a t i o n models, the UltraFlow 3000 and 4000. The hand-held portable systems are battery operated and can run for 20 continuous hours, while the ultrasonic systems offer stationary solutions for flow measurement; both systems can accommodate pipes that range in size from ½ to 78 inches O.D.

Submersible Level Transducers

Vortab Insertion Panel Flow Conditioner The Vortab Insertion Panel (VIP) Flow Conditioner has been designed to maximize the accuracy of air and gas flowmeter measurements. To do so, the conditioner offers a lightweight panel design, which is not only easy to install, but is also costeffective, in comparison to similar products. The conditioner is also available in either ANSI or DIN flange-mount or weld-in-place configurations.

A new product line of submersible level transducers, known as TruBlue, which measure water level and quality, offer a longer battery lifespan than other previously designed transducers. One TruBlue transducer, the TruBlue 555, has been developed to measure water levels in several types of environmental and watershed management applications, including ground water. The TruBlue 555 can also be used in various weather conditions and in temperatures ranging from 32° to 122° F.

GF Piping Systems

Fluid Components International

Pressure Systems

Tustin, Calif. •(714) 731-8800 www.gfpiping.com

San Marcos, Calif. • (800) 854-1993 www.fluidcomponents.com

Hampton, Va. • (800) 328-3665 www.TruBlueMonitor.com

JANUARY2012 www.pollutionengineering.com

11

Advanced

AIR POLLUTION CONTROL in

One System

Unlike other fifilter lter systems systems, aadvanced, dvanced low-density ceramic filter systems are now capable of removing particulate matter (PM), NOX, SO2, HCl, dioxins and mercury, all within a single system. By KEVIN MOSS dvanced, low-density ceramic filter systems are capable of removing particulate matter (PM), NOX, SO2, HCl, dioxins and mercury in a single system. Particulate matter is removed to ultralow levels (less than 2 mg per Nm3, 0.001 grains per dscf), while other pollutants can be eradicated at percentages greater than 90 percent.

A

Ceramic filters Ceramic filters, often called candles because of their solid tube shape, have been used in pollution control systems for decades. The original high-density candle filters were manufactured from refractory grains, including alumina or silicon carbide, and pressed into a basic candle shape – a tube with a closed, rounded bottom and a flange

at the top. Newer, low-density filters start as a slurry of refractory fibers and are vacuum formed. The contrast between each of these types of ceramic filter elements is shown in Table 1. There are currently hundreds of applications of these types of filters in Europe, Japan and Australia. Each of these filters can be placed in a housing module similar to a baghouse (see Figure 1). These lightweight ceramic filters solve many of the problems that are generally associated with “candle filters.” While effective, the latter were brittle and prone to cracking and breakage from thermal shock and vibration. As shown

Figure 1: Many filters placed in a single module. Multiple modules are operated in parallel to handle large volumetric flow rates.

in Figure 2, the fibers maintain a very high, open area for low resistance to airflow, minimizing pressure drop and the number of elements required for a given flow rate. Due to the high, open area, elements can also be cleaned using the standard reverse pulse-jet techniques

Left: Table 1, Above: Table 2

12

Pollution Engineering JANUARY2012

AIR POLLUTION CONTROL in One System that are associated with fabric filter baghouses (see Table 2).

Operating characteristics Ceramic filters must operate above the con d e n s a t i o n temperature of the pollutants, or else the particulate will not be released from the filter surface, unless the temperature is raised and the material volatilizes, thus cleanFigure 2: Micrograph ing the filter. of filter elements Table 3 shows composition. typical operating temperatures for the ceramic filters. The filters are chemically inert and highly corrosion resistant. Tri-Mer manufactures two varieties of filters: standard UltraTemp filters and UltraCat catalyst. The catalyst filter is identical to the standard filter, except that it has nano-bits of selective catalytic reduction (SCR) catalyst embedded in the filter walls for NOX removal and dioxin destruction.

the filter and does not deeply penetrate into the filter body, thus allowing for repetitive and complete cleaning. The filter does not blind, and the pressure tends to drop very gradually, typically lasting five to 10 years, to the point at which filters should be changed. Pressure drop for the new clean filter is approximately six inches w.g. The pressure drop can be lowered by adding more filter elements, and capital cost can be reduced by decreasing the filter count at the expense of fan horsepower. As a result of the filter construction, standard reverse pulse jet methods can thoroughly clean accumulated PM from the outer surface of the tube. Filters are cleaned on-line, with no need to isolate each housing module. The filters are effective across many particle sizes, but are most often used when there is a large fraction of PM2.5 and submicron particulate at high temperatures (see Table 4).

SO2 and acid gas control Particulate control The typical level of PM at the outlet of the ceramic filters is less than 0.001 grains per dscf. This is accurate even with heavy inlet loadings of several thousand milligrams per cubic meter. PM is captured on the face of

Both filter systems feature an option for dry injection of calcium or sodium-based sorbents. Injected in the duct upstream of the filter modules, additional sorbent particulate is captured along with its pollutant gas. The sorbent must be milled to a small

Table 3

particle size to maximize surface area for maximum reactivity. The reaction occurs within the duct, prior to the filter, and at the filter cake that builds up on the surface of the filters. The chemical reaction of the sorbent, along with the acid gas, creates a solid particle that captured on the filters alongside the unreacted sorbent and the process particulate. With sorbent injection, SO2 removal is typically 90 percent or higher, with removal efficiencies as high as 97 percent. On the other hand, HCl removal is normally 95 percent, and often as high as 99 percent. The temperature range for effective removal is 300°F to 1,200°F (See Figure 3 on next page). Sodium bicarbonate and trona are typical sodium-based sorbents. Trona is the ore from which soda ash and sodium bicarbonate are produced. When properly milled, trona can be used as a dry sorbent, requiring no other processing, and is available throughout North America.

Table 4 JANUARY2012 www.pollutionengineering.com

13

AIR POLLUTION CONTROL One System

in

NOX and dioxin control For NOX or dioxin removal, catalyst filter elements are available with nano-bits of SCR catalyst embedded in the walls. The filter walls containing the catalyst are about 3⁄4 inch (20 mm), as represented in Figure 4. Urea, or ammonia, is injected upstream of the filters. The embedded catalyst then

Figure 3: Standard filter system for control of particulate, SO2, HCl, and other gases

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Pollution Engineering JANUARY2012

destroys NOX, with up to 95 percent removal efficiency. Of note, the operating temperature required for high NOX destruction is 350°F to 400°F, compared to 600°F to 650°F for conventional SCR. Besides the need for high temperature, a common complication regarding traditional SCR is that the catalyst becomes poisoned and ineffective, necessitating early replacement. Typical poisons are ordinary PM, metals and HCl. The catalyst used in the filters is a proprietary formulation to improve performance. The increased reactivity at lower temperature is partly due to their micronized form. The diffusion restriction is eliminated, and the catalyst is almost completely protected from blinding by particulate matter, since it is sheltered inside the filter itself (see Figure 5). PM removal, sorbent injection for SO2 (and other acid gases) and catalytic reduction can be incorporated within a single system. It is important to note that operating temperature for high NOX removal must be kept between 350°F and 700°F to achieve NOX removal rates up to 95 percent. Dioxins are also broken down by the catalyst. Optimum performance for dioxins is limited to an upper temperature of 480°F. Destruction efficiency is typically 97 to 99 percent. Multi-pollutant capability creates a powerful, all-in-one-solution that is superior, in performance and economics, to having a separate pollution control device for each pollutant. There is often insufficient temperature to operate a traditional SCR for NOX removal. Low-temperature NOX removal provides flexibility for industrial processes requiring control (see Figure 6).

AIR POLLUTION CONTROL in One System

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Figure 4: Ceramic fiber filter tube with embedded nano-catalysts

Mercury control The ceramic filter systems are compatible with standard mercury removal techniques. Mercury control is notoriously difficult: each instance is individually analyzed and customized solutions are engineered. A few general observations can be made. The filters can handle high particulate loads while maintaining low outlet levels. Just as the addition of dry sorbents for the removal of acid gases is effective, so is the addition of powdered Figure 5: Micrograph of nano-catalysts activated carbon embedded in ceramic-coated fibers (PAC) for adsorbing mercury. In general, regular PAC becomes less effective withincreased temperature, topping out around 400°F. Under the right conditions, 70 to 80 percent control can be achieved. The chemical composition of the pollutant gas plays a major role. At higher temperatures, brominated PAC is required. According to the manufacturers of brominated products, temperatures of 500°F to 800°F are acceptable. Significant levels of mercury have also been captured in applications with injected powdered trona.

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What conditions favor ceramic filters? For particulate removal only, the standard ceramic filter can operate at temperatures as high as 1,650°F, exceeding the tempera-

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Figure 6: Control of PM, SO2, HCl, NOx, and dioxins

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AIR POLLUTION CONTROL One System

in

ture range of fabric bags. If temperatures remain below 400°F and there are no special circumstances, the fabric bags are less costly than ceramic filters. In borderline cases, the ceramic filters have a much longer element life and often prove to be the most cost-effective solution. In applications that require NOX removal, since fabric bags and ectro-

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Pollution Engineering JANUARY2012

static precipitators (ESPs) cannot control NOX, catalyst filters are preferable. Ceramic filters also replace (ESPs) when there is a Figure 7: Catalytic need for very low element performance PM levels, especially for applications with significant concentrations of PM2.5 and submicron particulate. The filters can handle much higher inlet loadings, are not subject to the selective removal constraints of ESPs, have lower maintenance requirements and fewer corrosion issues and are roughly equivalent (or lower) in energy usage. Because of the formation of filter cake on the filter surface, which provides more exposure to the acid gases, filter systems consume significantly less sorbent; consequently, higher removal efficiency can be achieved for acid gas removal. As stated, fabric bags and ESP do not remove NOX or dioxins. Therefore, a second technology (perhaps with additional temperature control) would also be required. In contrast, the catalyst filter can handle all of the pollutants in a single device and at lower temperatures (see Figure 7). The modular design of the housing units allows filters to be configured to handle large gas-flow volumes. When large flow volumes are treated, modules are placed in parallel. The systems are designed so that a single module can be taken off line if required, and the remaining two or more modules can continue to operate at a slightly higher pressure (designed into the fan) without interruption of the process itself, and with no appreciable change in emission control performance. Lightweight ceramic filters have been used for the last 10 years by the U.S. military at munitions-destruction facilities in Indiana, Utah and Oklahoma. Hundreds of ceramic filter applications are currently located throughout the world. PE For more information, please contact Kevin Moss, Tri-Mer business development director, advanced technologies. He may be reached at (801) 294-5422, or [email protected]. Visit www.tri-mer.com

Pollution Engineering takes a sneak peek into future technologies that could impact the environmental industry. By ROY BIGHAM, Editor, Pollution Engineering

W

ow!

This past year seemed to pass very quickly here. As hard as it may be to believe, it is already time to once again gaze into our crystal ball and cogitate on which types of technology is being developed that will make our little corner of the universe a better place to inhabit. As we peek into the future, please keep some points in mind. First, even though certain Congressional members will continue to self promote and take exception to what the EPA is trying to do, it would be political suicide to try to eliminate that governmental agency. Also, new technologies will continue to be developed and adopted to solve environmental problems so that our air remains clean and our water is fresh and free of contaminants. Consider this: politicians on both sides of the argument are currently claiming that job creation is – and will continue to be – a top priority. Also, environmental regulations have often been the driving force behind the fostering of new tech-

nologies that have driven environmental advancement. Remember, that not long ago, environmental scientists were still measuring at contaminations that were measured to the nearest one-thousandth concentration. Today, new technology allows concentrations to be determined to the nearest trillionth. That single improvement alone has led to technologies that can clean our air or water resources and lower contaminants that were heretofore unknown. Of course, somebody, somewhere has to build these new devices. Somebody has to operate the new gadgets and interpret the data. When I was in college, there were only a handful of schools that offered environmental science courses. Yet, today, a majority of the country’s colleges’ and universities’ curriculums include such courses. As a result, environmental science research continues to expand and provide additional jobs within the United States and abroad. Although the recession recently shrunk the ranks of the environmental professional, the Bureau of Labor Statistics still

claims that environmental scientist ranks will continue to grow – at least through 2018. But, which types of technological innovations and development will also help stimulate job growth, especially in 2012?

10. Safe, clean, unlimited energy

Without a doubt, the nation’s energy industry is always under attack. Consumers want more power for their flat screen TVs and other gadgets but the costs of providing that energy is rising too quickly. Environmentalists want everyone to be ultra conservationists and to survive on minimal power in order to limit the amount of energy that is consumed and thereby lowerair emissions. Amara D. Angelica is a unique person whose resume is just outstanding. She has worked with really elite companies and scientists in her career. In the 1960s, Dr. Peter Glaser proposed that a platform could be built in high Earth orbit to collect solar energy and

JANUARY2012 www.pollutionengineering.com

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Top 10 Technologies transmit it to the planet. It would be at least seven times more efficient than ground-based installations and, best of all, there would be no impact from clouds or inclement weather. On November 14, the National Space Society announced the conclusions of its three-year, 10-nation

feasibility study of this technology. The society believes that the technology capable of achieving this will be available within the next 10 to 20 years.

9.

Scratch that

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The specially designed polymer molecules that make up the solid item can be disassembled by the UV light so that they flow and fill in the cracks. When the light is turned off, the molecules reassemble themselves and the filled cracks become rigid again. Credit: Zina

Deretsky, National Science Foundation, after Burnworth et al., Nature, April 21, 2011 United States have previously teamed up to develop a special polymer-based coating that would self heal by shining light on it. This coating was developed with the automotive industry in mind. As a result, a simple scratch in a car’s paint could be repaired by shining an ultraviolet light on the impacted area. The material liquefies and then solidifies to look as good as new. Think of how this technology could also be a boon to the environmental industry. Many tanks and piping systems are specially made for wastewater applications. A scratch in the coating can lead to system failure, resulting in leaks or spills. Maintenance generally requires special paints that are difficult to apply and are expensive. This technology has the potential to cure many headaches.

8. Mixing electricity and water

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While safety professionals like to remind people that the mixture of electricity with water can be a deadly combination, such

Pollution Engineering JANUARY2012

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studies demonstrate the analyzer’s ability to perform in various applications, such as greenhouse gas monitoring, as well as flux networks and process applications. For more information on these studies and the IRIS platform, please visit our website, www.pollutionengineering.com,

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mixing within a wastewater treatment plant may be just the ticket to saving energy, as well as hundreds or even thousands of dollars. Municipal wastewater treatment facilities currently require large amounts of electricity to operate. This topic was seriously addressed at a Water Environment Federation meeting in early August 2011. While attendees discussed a variety of ways to reduce energy usage, the ideas that garnered the most interest involved the utilization of wastewater facilities to actually generate their own energy. In fact, it was suggested that these plants could even produce enough excess power that it could be sent to the grid. Other ideas, shared by attendees, were focused on growing algae to produce biofuels, while also gathering biogas from normal wastewater operations and micro-hydropower. By combining these and other technologies, along with power conservation measures, there would be an excess amount of power available that could be returned to the grid. Aside from the benefits of lowering costs, there would also be fewer odors and fewer greenhouse gas emissions. More information is available at visit www.wef.org.

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7. Seeing the light The documentation and reporting of greenhouse gas emissions is becoming increasingly important. As a result, the Thermo Scientific IRIS Platform of laser-

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Top 10 Technologies

7

Above, spectra of the three primary greenhouses gases are shown in the near-infrared and mid-infrared regions. For CO2, transitions are approximately 8,000 times stronger than those in the near infrared.

go to the white paper pages and click on the Air tab to view the full Greenhouse Gas Monitoring white paper.

6. Unsaturated

vadose cleanup

Treatment methods of contamination in the vadose zone have been limited to excavation or soil vapor extraction. Unfortunately, each of these methods have had various issues, depending on the type of con-

tamination and the type of soil in the vadose zone. EOS Remediation LLC, located in Raleigh, N.C., teamed up with the Department of Energy’s Brian D. Riha, from the Savannah River National Laboratory, headquartered in Aiken, S.C., to develop a patented process known as Vadose Organic Substrate (VOS). VOS is a thixotropic formulation of biodegradable vegetable oil, water, nutrients and buffer that can be used in conjunction with a dechlorinating inoculum (Dehalococcoides sp.). Once placed in the soil, the materials will stay in position to treat the offensive materials. Simple technology can be applied to track the progress of the material in the soil matrix so that the client is assured of proper contact. Field testing by Savannah demonstrated the material was safe to handle and did not require special injection equipment. The material sets up to a gel consistency after injection so that it not only resists being washed away, but also continues to promote conditions for anaerobic reduction biodegradation of many contaminants, while using a scientific combination of organic electron donors and nutrients. More information in regards to this material will be included in an upcoming edition of Pollution Engineering.

5.

Mobil monitoring and control

Bobby Sheikhan, senior project manager for RAE Systems, has told Pollution Engineering that his company is releasing new families of wireless monitoring systems. The company is also focused on improving the communication capabilities of existing control systems and mobile devices, including smartphones and tablets. Since environmental professionals

5

The RAE Systems BioHarness includes ECG and breathing rate sensors for real-time portable physiological monitoring. The BioHarness links to a RAELink3 portable modem to transmit sensor readings and GPS coordinates to a PC running rhe RAE Systems ProRAE Guardian safety monitoring software

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Pollution Engineering JANUARY2012

Top 10 Technologies are often called upon to enter suspicious areas or confined spaces, the company also provides a special harness that constantly monitors the health and conditions of individual users to ensure safety in such potentially hazardous conditions. The non-intrusive, lightweight chest worn strap incorporates an electrocardiogram, breathing rate, temperature, posture and activity sensors for real-time portable physiological monitoring to quickly access and monitor a person’s bio-readings, and back them out of a fatigue situation if their readings are high.

3. CO2 in, energy out

2. Wasted nutrients

Researchers at the University of Minnesota’s Institute on the Environment know a lot about geothermal energy. They have also studied the concept of pumping CO2 from the surface to deep underground for permanent storage. These same researchers have recently asked themselves why they could not accomplish both tasks at the same time. This would lower greenhouse gases and provide a completely renewable source of energy. Consequently, the institute has completed pilot studies that demonstrated the feasibility of such an undertaking. They are preparing to take the next step to form a startup around the technology to show that it can be implemented profitably on a larger scale. They hope to ultimately demonstrate that this is a viable application for many areas of the country.

Every budding green thumber knows how valuable potassium, nitrogen and phosphorus are for keeping plants healthy. At one time, scientists were convinced that these three chemicals were all that plants needed in order to thrive. They reached this conclusion because these were the only compounds that were identified when performing chemical analysis. Today, thanks to improved analytical techniques, we know that trace metals are also critical to the growth of healthy, nutritious plants. Currently, raw sources of potassium and nitrogen are plentiful throughout the world. Unfortunately, 84 percent of the known resources of phosphorous are located in a single location – Morocco. There are alternative sources of phosphorous that have been deployed for many decades though, as high concentrations are known to exist in natural waste prod-

4 4. Recession creates opportunity

In recent years, the national economy’s influence on the U.S. housing market and business has been well documented. Thousands of properties currently lay abandoned and are deteriorating. Yet, this condition may also be providing opportunities to many cities. The Georgia Institute of Technology has been working with a number of cities. In five of the major cities, the institute has identified more than 20,000 acres of land that can be recovered to the benefit of local communities. The community enrichment program is known as Red Fields to Green Fields. While each city is unique, they all have thousands of acres that can be recovered and transformed into attractive properties. Once the economy recovers, these properties will be premium locations as they will include upscale greenscapes that will draw business or residential attention. The additional attention should result in an increased tax base. Because of the new landscapes, there would be an improved draw for customers to the new businesses.

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10 Top ucts from animals and humans. In fact, excess phosphorous is a real headache at wastewater treatment plants. The chemical forms crystals and precipitates out on the sides of tanks and piping, forming a rock-hard material called struvite. A Vancouver-based company, known as Ostara Nutrient Recovery Technologies Inc., has developed a process that captures this material in order to provide a substance that is particularly suited for agricultural use. So far, it has been installed in wastewater treatment systems in Canada, the United Kingdom and the United States.

1. Superior engineering While some activists complain about the damage caused by dams interrupting the natural flow of water, American universities are presently studying the most accomplished dam builder in the world – the beaver. Activists and researchers agree that many

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Pollution Engineering JANUARY2012

1 rivers need to be restored. Restoration work can be very expensive though, as engineers strive to mold the landscape to provide the maximum benefit after a dam is constructed. There are many factors that need to be taken into account in the design.

“Our argument is that the restoration target for streams with forested riparian zones has got to acknowledge the diversity brought to river systems by active beaver populations,” said Melinda Daniels, an associate professor of geography at Kansas State University. Daniels collaborated with three researchers from the University of Connecticut to co-author The River Discontinuum: Applying Beaver Modifications to Baseline Conditions for Restoration of Forested Headwaters. Beavers were nearly driven to extinction early in the 19th century due to over hunting. Their populations have since recovered. The Kansas State University and University of Connecticut researchers are closely studying the work of beavers in nature in Connecticut. They believe their work would be applicable to river systems across the county. There is definitely a lot to be learned from the beavers and, after all, who could possibly do a better job than Mother Nature herself? PE

REVERSE OSMOSIS Membrane Processing APPLICATIONS INSIGHTS How can reverse osmosis technology be applied to wastewater and process water to maximize efficiency?

By PETER S. CARTWRIGHT, P.E. lthough the reverse osmosis membrane technology was developed many years ago, additional applications at water treatment facilities are still being developed. While the source of the water to be treated does not influence the technology’s capabilities, its performance and design requirements are significantly affected by feed water characteristics and the intended use of the treated water. In general, it is useful to divide the feed water into three categories: • Raw water – water from a natural source, such as a well, river, lake, or ocean, or from a municipal drinking water treatment plant • Wastewater – water that flows out of an industrial or commercial facility or a sewage treatment plant • Process water – wastewater used in a manufacturing process As water reclamation and reuse is continuously emphasized, it is important to understand the distinctions between these source waters and their impacts on membrane system designs. Sources of raw water, including seawater, have a relatively narrow range of chemical characteristics and are well understood and present minimal design challenges. For

A

example, to design a reverse osmosis treatment system with spiral-wound membrane elements, membrane manufacturers provide a computer program to design a water purification system, as long as they have some technical understanding of the materials. It is only necessary that this person know and understand the following: • Feed water analysis • Purified water quality requirements • Total volume requirement (per day, per minute) • Desired system recovery A typical membrane process is illustrated in Figure 1.

Raw water The primary goal for most water purifica-

Feed Stream

tion applications is to meet a specific treated water-quality requirement, while system recovery is usually a second requirement. System recovery is the percentage of feed water flow that passes through the membrane and becomes the permeate. Recovery is the purview of the system designer, and typically ranges from less than 50 percent for low flow applications to 85 percent for very large applications. One advantage of high recovery designs is that a relatively small quantity of concentrate (that percentage of the water that does not pass through the membrane and carries away the contaminants removed from the water supply) is discharged. Due to these lower flow rates, other advantages include a smaller feed pump and generally smaller pipe sizes.

Permeate Stream

Valve Figure 1: Typical Membrane Process

Concentrate Stream JANUARY2012 www.pollutionengineering.com

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A primary goal of reverse osmosis membrane processing is to decrease the concentrate stream so that it is as small as possible in order to facilitate further treatment or disposal. Therefore, recoveries are generally set very high, typically above 90 percent. Additionally, in the case of most industrial wastewater streams, the water characteristics are usually unique. Consequently, testing should be performed in order to develop system design data. This testing can take the form of cell testing, applications testing and/ or pilot testing, but it is absolutely essential in industrial wastewater applications. None of the currently available computer programs are capable of designing an effective wastewater treatment system. For reverse osmosis, the ionic concentration increases (resulting from the effects of high recovery) Since the mechanism involves a percent rejection of salts (typically above 90 percent), a percentage (albeit small) of the salts concentration at the membrane surface will pass through the membrane into the permeate stream (100 minus the percent rejection). As the concentration of salts increases due to higher recovery operations, an elevated quantity will pass through the membrane, thereby lowering the quality of permeate. This high recovery will also produce an elevated osmotic pressure in streams that have significant salts content. Osmotic pressure is basically the resistance of an ionic solution to being pumped through a reverse osmosis or nanofiltration membrane, and is a function of both the type of salts and their concentration. It is important to remember that the concentration of contaminants seen by the membrane is roughly the arithmetic average of the feed and concentrate streams. Under high recovery conditions, the concentrate stream concentration is extremely high, which will increase the average con-

centration. Therefore, the TDS of the feed stream does not have to be particularly high to result in a high osmotic pressure condition. One of the outcomes of a test program is the determination of osmotic pressure as a function of recovery for a given waste stream. An important parameter for wastewater applications is to decide the ultimate discharge of the concentrate stream. Depending upon the situation, options include evaporation to dryness, collection in an ion-exchange resin or other adsorptive medium, or simply the removal of this stream for disposal.

Process water Of the three general applications for membrane technologies, chemical processing is the most complex and diverse. Membranes are used for applications where certain contaminants are separated from each other into discrete streams, and then one or more are possibly recovered for reuse.

Testing requirements With regard to wastewater and process water applications, it is imperative that every stream be tested to identify the following design factors: • Optimum membrane element configuration • Total membrane area • Specific membrane polymer • Optimal pressure • Maximum system recovery • Flow conditions • Membrane element array • Pretreatment requirements Specific properties of feed streams, which influence these design factors include: ■ Stream chemistry • Total solids content • Suspended (TSS) • Dissolved organic (TOC, MBAS, COD and BOD) • Dissolved inorganic (TDS) ■ Chemicals of concern • Oxidizing chemicals • Organic solvents (particularly aromatic hydrocarbons) • Saturated solutes ■ pH ■ Operating temperature

REVERSE OSMOSIS Osmotic pressure as a function of system recovery ■ Variation in chemistry as a function of time To generate necessary design data, several testing options are available: Cell Testing – Cell test devices are available for purchase or a qualified consulting engineering firm can provide testing. Such testing will evaluate small sheets of membrane candidates on the stream to be processed. Typically, the sheet is placed between two stainless steel plates, and the test stream is pumped across the membrane surface at a selected pressure and flow rate. The permeate is collected and analyzed for its degree of solute separation. Cell testing only requires small volumes of the test solution. Several membranes can be evaluated in a short period of time. The cell test approach is useful as an initial step, primarily to select one or more membrane candidates for further evaluation. However, actual final design cannot be developed from this test. Applications Testing – Applications testing utilize a full-sized membrane element in a test unit that is capable of simulating a production unit. Since the data from this testing will be used to scale up the design to full size, it is essential that the membrane element manufacturer supplies an element that is capable of such scale up. The applications test equipment should be designed so that very high recoveries can be achieved without compromising the flow rates required to produce turbulent flow. This requires a pump that is capable of not only producing the desired pressure, but also a flow rate to create the minimum cross flow velocity across the membrane surface as well. Materials of construction should be considered prior to testing; 316L stainless steel is essential for most applications requiring pressures in excess of 60 psi; below that, schedule 80 PVC is usually sufficient. For high chloride streams, special alloys may be required. Applications testing can generate complete design data for the full-sized system. The test can be conducted with ■

as little as 50 gallons (200 L) of the test stream, and, after setup, can be completed in one hour or less for each membrane element tested. A typical applications test is conducted as follows: 1. To establish control conditions, high quality water (tap water or water treated with reverse osmosis or a deionizer) is used in the system at low recovery. Record data for each condition. 2. Feed water is then initially tested in the unit at a low recovery. After the system stabilizes, (usually in less than five minutes), the following data are recorded: feed pressure, pump pressure (pump discharge), system pressure (at the exit of the membrane upstream of the concentrative valve), recycle pressure, flow rates (usually feed, recycle and permeate) and recycle stream temperature. The system recovery is then increased incrementally while adjusting the recycle to ensure that the correct cross flow velocity is maintained. At each recovery, in addition to the collection of flow and pressure data, analytical samples may be taken for performance evaluation. Of course, the choice of chemical parameters to be measured depends upon the separation goals of the test. It is unusual for system recoveries to exceed 95 percent; however, recoveries also depend upon the goals of the testing, and it is possible to run a well-designed test unit up to 99 percent recovery. Once the optimum conditions have been established, such as operating pressure and maximum system recovery, the normalized performance data will enable the test engineer to determine the total membrane area required for the full-sized system. Pilot Test – This test involves the operation of a prototype system that can be scaled up as needed in the final design. This usually involves the placement of a test machinein the process, which operates continuously on a side-stream for a minimum of 30 days. The optimum run conditions (recovery, pressure, flow rates, etc.)

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REVERSE OSMOSIS Table 1 – Testing Options (Spiral-wound membrane element)

Characteristic

Membrane Size

Applications

Pilot

4" x 6" Sheet

4” dia X 4“ len Spiral Element equivalent in other device configurations)

4” dia X 4“ len Spiral Element equivalent)

Volume of Test Solution