Case study - Rockwood Pigments chooses Beltran System

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Courtesy of Beltran Technologies, Inc.

Rockwood Pigments, a global manufacturer of pigment products, has chosen a wet electrostatic precipitator (WESP) system engineered by Beltran Technologies, Inc.. to clean process gas streams before entering a sulfuric acid plant at its Easton, Pa., manufacturing facilities.

Rockwood is the world's second laraest manufacturer of iron oxide and other inorganic color pigments used by paint and coatings producers to add vibrant, long-lasting color to an array of materials, products and structures. The company's Easton operation includes a sulfuric acid plant, which produces commercially valuable   sulfuric   acid   from   SO,

gases exhausted from its iron sulfate roasters, an intermediate step in the pigment manufacturing process. The company has found Beltran's WHSP technology ideally suited to removing iron oxide. SCX. sulfuric acid mist and other impurities from the gas before it goes to their sulfuric acid plant— an essential step for the protection of downstream processing equipment and the production of a pure, high-quality sulfuric acid product. Beltran precipitators are especially efficient at capturing and removing fine, submicron particulates, acid mists and condensable organics. The system designed and engineered for Rockwood has achieved an overall efficiency of >99.5 percent.

The corrosive nature of Rockwood's flue gases demanded that special attention be given to the materials of construction. The Beltran WESP was fabricated using fiberglass reinforced plastic (FRP) and high nickel-chromium alloys instead of lead, which historically has been used in precipitators designed to clean acid mist. Besides being extremely  corrosion   resistant.  FRP precipitators are also less expensive and easier to construct and maintain. The electrically conductive sections of the WESP are made from special conductive FRP.

Untreated sulfur dioxide gases from metallurgical processes such as ore roasters, flash smelters and spent acid regenerators must be cleaned before entering the sulfuric acid plant. To prevent the formation of 'black' or contaminated acid and to protect the catalyst beds from fouling and plugging, electrostatic precipitators are normally used to remove acid mist, fine particulates, condensed organics and fumes before these gases enter the drying tower.

Conventional scrubbing systems, wet or dry, are generally not effective in controlling submicron components of these flue gas emissions. Wet tubular electrostatic precipitators, because of their ability to generate multistaged charging and strong electrical fields in a wet. cooled atmosphere, have proven more effective in cleaning these gases.

The Beltran WESPs utilize ionizing rods with star shaped discharge points in a square or hexagonal configuration. This unique geometry generates a corona field four to five times more intense than other wet or dry ESPs. enabling the Bcltran system to operate at >99.5 percent efficiency on submicron particulates and acid mists, as demonstrated at Rockwood Pigments.

Wet operation using a recirculating water spray to clean collection surfaces virtually eliminates the re-entrainment problem common to dry ESPs and other technologies. It also eliminates the need for mechanical and/or acoustic rappers. There is minimal impedance and pressure drop compared to scrubbers and other methods, enabling faster throughput and the use of simpler, smaller scale, less expensive components. The superior performance of Beltran WESPs has resulted in more thorough cleaning, enhanced efficiency, greater energy savings and lower total operating costs for Rockwood Pigments.

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