air-pollution-control

Air Pollution Control Design Skill

Air pollution control equipment selection and design for industrial emission reduction.

Purpose

This skill provides comprehensive capabilities for designing air pollution control systems, including technology selection, equipment sizing, efficiency calculations, and regulatory compliance demonstration (BACT/LAER/MACT).

Capabilities

Scrubber Design

• Wet scrubber technology selection
• Packed tower design and sizing
• Spray tower configuration
• Venturi scrubber design
• Pressure drop calculations
• Liquid-to-gas ratio optimization
• Chemical dosing requirements

Baghouse and Fabric Filter Sizing

• Filter media selection
• Air-to-cloth ratio determination
• Compartmentalization design
• Pulse-jet vs reverse-air cleaning
• Pressure drop estimation
• Bag life prediction
• Hopper sizing

Electrostatic Precipitator Design

• Collection efficiency calculation
• Specific Collection Area (SCA) determination
• Plate spacing and configuration
• Electrical field strength
• Rapping system design
• Resistivity considerations
• Power supply sizing

Thermal and Catalytic Oxidizer Specification

• Destruction efficiency requirements
• Temperature and residence time
• Heat recovery options (regenerative, recuperative)
• Catalyst selection for catalytic oxidizers
• Auxiliary fuel requirements
• Turndown capabilities

Carbon Adsorption System Design

• Activated carbon selection
• Adsorption capacity calculations
• Breakthrough time estimation
• Bed sizing
• Regeneration system design
• Carbon replacement frequency

Control Efficiency Calculations

• Outlet emission rate determination
• Removal efficiency verification
• Stack testing correlation
• Continuous monitoring requirements

Pressure Drop and Energy Analysis

• System pressure drop calculation
• Fan power requirements
• Operating cost estimation
• Energy optimization opportunities

BACT/LAER/MACT Determination

• Control technology identification
• Cost-effectiveness analysis
• Technical feasibility evaluation
• Regulatory database research
• Top-down BACT analysis

Prerequisites

Installation

pip install numpy scipy pandas matplotlib

Optional Dependencies

# For chemical property lookup
pip install chemicals thermo

# For visualization
pip install plotly

Usage Patterns

Baghouse Design

import numpy as np
from dataclasses import dataclass
from typing import Dict, List, Optional

@dataclass
class GasStreamData:
    """Gas stream characteristics"""
    flow_rate_acfm: float
    temperature_f: float
    moisture_pct: float
    particulate_loading_gr_acf: float
    particle_size_micron: float
    gas_composition: Dict[str, float] = None

@dataclass
class BaghouseDesign:
    """Baghouse design parameters"""
    filter_media: str
    bag_diameter_in: float
    bag_length_ft: float
    air_to_cloth_ratio: float
    cleaning_type: str  # 'pulse_jet', 'reverse_air', 'shaker'

class BaghouseCalculator:
    """Pulse-jet baghouse sizing calculations"""

    # Recommended air-to-cloth ratios (acfm/ft2) by application
    AC_RATIOS = {
        'cement': {'gross': 4.0, 'net': 3.5},
        'coal': {'gross': 6.0, 'net': 5.0},
        'foundry': {'gross': 4.5, 'net': 3.5},
        'steel': {'gross': 5.0, 'net': 4.0},
        'chemical': {'gross': 5.5, 'net': 4.5},
        'pharmaceutical': {'gross': 3.5, 'net': 3.0},
        'general': {'gross': 5.0, 'net': 4.0}
    }

    # Filter media properties
    MEDIA_PROPERTIES = {
        'polyester': {'max_temp_f': 275, 'cost_factor': 1.0, 'acid_resist': 'good'},
        'polypropylene': {'max_temp_f': 200, 'cost_factor': 0.9, 'acid_resist': 'excellent'},
        'nomex': {'max_temp_f': 400, 'cost_factor': 3.0, 'acid_resist': 'good'},
        'fiberglass': {'max_temp_f': 500, 'cost_factor': 2.5, 'acid_resist': 'excellent'},
        'ptfe': {'max_temp_f': 500, 'cost_factor': 8.0, 'acid_resist': 'excellent'},
        'p84': {'max_temp_f': 500, 'cost_factor': 5.0, 'acid_resist': 'good'}
    }

    def select_filter_media(self, gas: GasStreamData) -> str:
        """Select appropriate filter media based on gas conditions"""
        temp = gas.temperature_f

        suitable = []
        for media, props in self.MEDIA_PROPERTIES.items():
            if props['max_temp_f'] >= temp:
                suitable.append((media, props))

        # Return lowest cost suitable media
        suitable.sort(key=lambda x: x[1]['cost_factor'])
        return suitable[0][0] if suitable else 'ptfe'

    def calculate_filter_area(self, gas: GasStreamData,
                              application: str = 'general',
                              use_net_ratio: bool = True) -> Dict:
        """Calculate required filter area"""
        ratios = self.AC_RATIOS.get(application, self.AC_RATIOS['general'])
        ac_ratio = ratios['net'] if use_net_ratio else ratios['gross']

        filter_area = gas.flow_rate_acfm / ac_ratio

        return {
            'gas_flow_acfm': gas.flow_rate_acfm,
            'air_to_cloth_ratio': ac_ratio,
            'filter_area_sqft': filter_area
        }

    def size_baghouse(self, gas: GasStreamData,
                      bag_diameter_in: float = 6.0,
                      bag_length_ft: float = 10.0,
                      application: str = 'general') -> Dict:
        """Size complete baghouse system"""

        # Filter media selection
        media = self.select_filter_media(gas)

        # Calculate filter area
        area_calc = self.calculate_filter_area(gas, application)
        required_area = area_calc['filter_area_sqft']

        # Bag area calculation
        bag_area = np.pi * (bag_diameter_in / 12) * bag_length_ft  # sq ft per bag

        # Number of bags
        num_bags = np.ceil(required_area / bag_area)

        # Compartments (typically 8-16 bags per row, 2-4 rows per compartment)
        bags_per_compartment = 32  # typical
        num_compartments = np.ceil(num_bags / bags_per_compartment)

        # Pressure drop estimate (typical for pulse-jet)
        dp_filter = 2.5  # inches w.c. for clean filter
        dp_tubesheet = 0.5
        dp_inlet_outlet = 1.0
        total_dp = dp_filter + dp_tubesheet + dp_inlet_outlet

        # Hopper sizing (4:1 turndown, 8-hour storage)
        dust_rate_lb_hr = gas.particulate_loading_gr_acf * gas.flow_rate_acfm * 60 / 7000
        hopper_volume = dust_rate_lb_hr * 8 / 50  # 50 lb/cf bulk density

        return {
            'filter_media': media,
            'required_filter_area_sqft': required_area,
            'bag_diameter_in': bag_diameter_in,
            'bag_length_ft': bag_length_ft,
            'area_per_bag_sqft': bag_area,
            'total_bags': int(num_bags),
            'num_compartments': int(num_compartments),
            'air_to_cloth_gross': gas.flow_rate_acfm / (num_bags * bag_area),
            'pressure_drop_in_wc': total_dp,
            'dust_rate_lb_hr': dust_rate_lb_hr,
            'hopper_volume_cf': hopper_volume,
            'max_temp_f': self.MEDIA_PROPERTIES[media]['max_temp_f']
        }

# Example usage
gas = GasStreamData(
    flow_rate_acfm=50000,
    temperature_f=350,
    moisture_pct=8,
    particulate_loading_gr_acf=2.0,
    particle_size_micron=5
)

calculator = BaghouseCalculator()
design = calculator.size_baghouse(gas, application='cement')

print(f"Filter media: {design['filter_media']}")
print(f"Total bags: {design['total_bags']}")
print(f"Compartments: {design['num_compartments']}")
print(f"A/C ratio: {design['air_to_cloth_gross']:.2f} acfm/sqft")
print(f"Pressure drop: {design['pressure_drop_in_wc']:.1f} in w.c.")

Wet Scrubber Design

class WetScrubberDesign:
    """Wet scrubber design calculations"""

    def packed_tower_sizing(self, gas_flow_acfm: float,
                           pollutant: str,
                           inlet_conc_ppm: float,
                           outlet_conc_ppm: float,
                           scr