Air Gas Cleaning&Odor Control-Monroe Environmental

8/10/2019 Air Gas Cleaning&Odor Control-Monroe Environmental

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www.mon-env.com

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For over forty years, Monroe Environmental hasbeen designing and manufacturing air qualitysystems for industrial manufacturers, government

agencies, and municipal treatment plants.

Complete Air Quality SolutionsMonroe Environmental offers a broad range

of stand-alone equipment as well as completesystems to effectively manage dust, mist, odors, andfumes associated with both industrial manufactur-ing and municipal water/wastewater treatment.

Monroe continues to solve challenging airand gas cleaning problems with our skilled team of

engineers, shop technicians, and knowledgeablesales staff. The largest manufacturing companies inthe world routinely look to Monroe to solve theirmost demanding mist, dust, and fume controlproblems.

Monroe Systems and Services Packed Bed Wet Air Scrubbers Venturi Particulate Scrubbers Carbon Adsorbers Multi-Stage Scrubbing Systems Dust Collectors Oil Mist Collectors

Design and manufacture new air qualityand odor control systems

Retrot existing systems to maximizeperformance and removal efficiency

Ductwork design Permit assistance for EPA compliance Industrial and municipal applications Turnkey systems available

The Monroe Advantage

Table ofContents

2 The MonroeAdvantage

4 ScrubbingApplications

6 Packed BedFume Scrubbers

8 VenturiParticulateScrubbers

10 CarbonAdsorbers

12 Multi-StageScrubbingSystems

14 Mist and DustCollection

16 Dry DustCollectors

18 Oil MistCollectors

0 Water andWastewater

Treatment

Stainless steel Multi-Stage Scrubbing System to treatexhaust from a toxic gasincineration process

15,000 CFM Packed Bed Scrubber to remove ethyl glycol and NMP fumes from a glass coating operat


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Packed Bed Fume ScrubbersIn a Packed Bed Scrubber, solublechemi-

cals, fumes, and odors ow through a speciallydesigned packing media that is irrigated with

recirculating scrubbing solution. The liquidsolvent absorbs the gas-phase pollutant byphysical and chemical means. A blowdown fromthe tank with makeup water addition removescontaminant pollutants before they precipitatein the reservoir. Packed Bed Scrubbers havea wide range of industrial and municipalapplications. Capacities: 10 to 75,000 CFM with a

single unit Efficiencies to 99.99% Vertical and horizontal models Counter-ow or cross-ow models Rectangular or cylindrical construction

designs Single and multiple stage designs Pre-quench and venturi stages available Pilot systems available for application and

process testing

Design Features Wide range of packing media available

including rings, saddles, loose-ll, andstructured packing in a variety of materials

Complete instrumentation and electricalcontrols are available for stand alone operationor connection with a facilityscentralizedcontrol or monitoring systems

Chemical treatment, including oxidationand neutralization, is available to increaseabsorption of gaseous pollutants

pH control available when applicable Corrosion resistant AMCA rated fan on the

inlet or outlet side of the scrubber Corrosion resistant recirculating pumps for

scrubber liquid recirculation Non-plugging spray nozzles or specialty liquid

distributors available for packing irrigation Moisture eliminators with chevron, mist pad,

or loose ll type designs

Materials of Construction Stainless steel & mild

steel FRP & FRP-lined mild

steel PVC & CPVC

Polypropylene Polyethylene Nickel alloys &

titanium

Non-plugging spray nozzles above bed of loose ll polypropylene packing

3,500 ACFM High temperature scrubbing system, stainless steel construction with inletquench and vertical packedbed for SO 2 removal from RTOexhaust

Skid-mounted Packed Bed Scrubber, FRP constructcustomized instrumentation, piping, pumps, and co panel fully assembled in Monroe shop


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7Vertical Packed Tower Air Scrubber Horizontal Packed Bed Air Scrubber

Moisture

Eliminator

SprayNozzles

TowerPacking

AirInlet

Liquid Reservoir

Clean AirDischarge

Vertical Packed BedFume Scrubber

This is a counter-ow design that has contami-nated gas owing upwards and recirculated liquidspraying downwards through the packing media.Vertical scrubbers typically have a smaller footprint

and can have greater removal efficiency thanHorizontal Packed Bed Scrubbers. Multiple scrub-bing stages with different scrubbing solutions canbe achieved by having more than one scrubbingtower in series (see page 12). Multiple towers providethe highest removal efficiency, as well as multiplegas constituent removal.

Horizontal Packed BedFume Scrubber

This is a cross-ow design that has recirculatedscrubbing liquid owing vertically downwardswhile the gas passes horizontally through thepacking section. This design is more tolerant of solid

particulate that may be contained in the air stream.A Horizontal Packed Bed Scrubber is appropriatewhen limited headroom is an issue, and it alsoallows for multiple stages in one housing withseparate sumps and scrubbing solution pumps ifrequired.

13,500 CFM skid-mounted Horizontal Packed Bed Scrubber, stainless steel construction to scrub acid andcaustic fumes

3,500 CFM Packed Tower Scrubber, PVC construction forHCl removal We will analyze

Contaminant solub Vapor pressures Wash liquid ow ra Liquid to gas ratio Packing chamber

dimensions Packing media typ

and size Chemical additives pH control Precipitation of

reaction products Required scrubbin

stages Pressure drop acro

packing Materials of constr Site requirements

PackingMedia

MoistureEliminator

Liquid RecirculatingPump

Fan/MotorAssembly

Air/GasInlet

CleanAir/GasOutlet


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Dual Throat VenturiWet Air Scrubber

The Monroe Dual Throat Venturi Air Scrubber isa completely self contained unit that needs only tobe connected to normal plant electrical, water, andair systems. It is one of the most versatile venturiscrubber designs available because of its ability tohandle a wide range of dry, wet, sticky, tacky, andoily particulate loads.

Recirculate Clean AirIn many installations, such as buffing and

polishing, metal nishing and grinding, foundryoperations, etc., it is possible to recirculate clean,contaminant-free air back to the work area. Thisreduces the cost of plant ventilation systems andclimate control needs.

Adjustable Scrubbing ThroatsHigh velocity atomization takes place as the

inlet air is directed through the xed and dualadjustable scrubbing throats. The easily adjustabledual throats balance the pressure drop through theairow system at start-up or after system changesare made. This design feature eliminates the needfor ductwork dampers and blast gates that areprone to particulate build-up and require periodicmaintenance. In addition, the increase in pressuredrop in the scrubbing venturi improves the overallefficiency of the system.

2,800 CFM Dual Throat Wet Air Scrubber, stainless steel construction with pyramid hopperfor sludge dryer exhaust scrubbing

Dual Throat Wet Air Scrubber with drag conveyor option

Features:

Wet type dustcollector

Efficiencies to 99.99 500-50,000 CFM

standard unitcapacities, specialdesigns available

No moving parts inthe scrubbing zone

Minimummaintenance

Optional solidsremoval conveyor

Optional oil skimminsystems

Chevron mist eliminator

9,600 CFM Dual Throat Venturi Scrubber for boilerexhaust scrubbing

Adjustable scrubbing throats

AdjustableScrubbing

Throats

WashLiquid

SolidsDischarge

OptionalDrag Conveyor

Air Inlet

Clean AirDischarge


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CleanAir/GasOutlet

Air/GasInlet

Prelter

Fan/MotorAssembly

A

A

Clean AirChamber

Section A-A

ActivatedCarbonRemovalHatch

Base

ActivatedCarbonAccess HatchClean Air

Chamber

InletChamber

Monroe Environmental manufactures DryAdsorbers for both physical and chemicaladsorption of gas-phase pollutants. Adsorption

involves the adhesion of pollutant gas moleculesto porous solid surfaces that the contaminated airstream passes through. Physical adsorption relieson intermolecular forces while chemical adsorptioninvolves the formation of chemical bonds.

Ideally Suited For Removal of H2S and other odors from municipal waste-

water treatment plant sources includingheadworks, digesters, and sludge dewateringoperations

Removal of VOCs, oil vapors, and gas phasehydrocarbons

Recovery of solvents including alcohols,esters, ketones, aromatic compounds, andhalogenated solvents

Industrial emissions from: degreasing, paintspraying, paper coating, plastic lm coating,metal foil coating, rubber-coating, semiconduc-tor manufacture, and printing

Overview of Adsorber TypesDeep Bed Adsorber: In horizontal or verticalconguration with a single deep bed or multiplebeds in series within the adsorber vessel.

Carbon Tray Adsorber: Flow passes throughseveral removable carbon trays in parallel. Each traycontains activated carbon pellets and can be easilyremoved and relled when pellets are saturated.

Parallel Bed Adsorber: Airow passesbetween two parallel beds in horizontal or verticalconguration, allowing higher airow because

there is a large passageway for initial contact of gaswith both of the adsorbent beds.

Carbon Adsorbers

Deep Bed Carbon Adsorber Parallel Bed Carbon Adsorber

Monroe DryAdsorptionunits providehighly efficient,continuous odorand pollutantremoval with aminimal footprint.

Deep Bed Carbon Adsorber with stainless steel hou

AccessHatch

AccessHatch

CarbonBed

Air/GasInlet

CleanAir/GasOutlet

Pre-lter


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200 CFM Carbon Adsorber, FRP construc-tion, with control panel for H 2 S removalat a municipal lift station

CarbonAdsorberFeatures Wide range of

adsorbents includingactivated carbon,zeolite, and syntheticpolymers

Capacities up to50,000 CFM for asingle unit

Multiple unit or singunit designs

Efficiencies to 99.99

8,000 CFM Carbon Tray Adsorber for a recycling facility, shop assembledwith stainless steel housing and differential pressure gauge

(2) 15,000 CFM Deep Bed Carbon Adsorbers, mild steel construction with specialty exhaust stacks for odor control at a grease manufacturing facility


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Multi-Stage System ScrubbersMonroe Environmental can provide complete

multi-stage air scrubbing systems for a wide varietyof applications. High temperature and volatile

chemical processes often require a more complex,customized air scrubbing solution than what asimple packed tower scrubber or venturi particulatescrubber can provide.

In many cases, several technologies must beintegrated together to provide adequate removaland treatment efficiencies. Monroes experienceincludes the engineering and fabrication of custom-ized multi-stage scrubbers utilizing the followingequipment:

Packed Bed Scrubbers Venturi Particulate Scrubbers Carbon Adsorbers Quench Towers Cyclonic Separators Heat Exchangers Fiberglass Filters Specialty Ducting Systems Clariers and Oil Recovery Units

Monroe has the experience and knowledge toevaluate your process and recommend a custom-ized scrubbing system for your specic application

Monroe has successfully treated contaminated airstreams resulting from: Solid waste and/or chemical gas incineration Kiln & RTO exhaust scrubbing Flame laminating and glass coating Grease & chemical production Textile manufacturing Chemical and compound reclamation High temperature scrubbing processes

And many others

Multiple Packed BedScrubbing Stages

Multiple scrubbing stages withdifferent scrubbing solutions canbe achieved by providing multiplescrubbing towers in series.

This type of system is commonwhen there is a high pollutant loading,multiple pollutants, or when removalefficiencies greater than 99.9% arerequired.

The diagram to the right includesthree towers in series that could beused for H2S and NH3 removal, HCland SO2 removal, or a variety of otherharmful gas combinations.

Right: Multi-Stage Scrubbing system with inletquench, 3-stage Packed Bed Scrubber, highenergy Venturi Scrubber, electric gas reheater,and Carbon Adsorber for toxic gas incineration

MonroeScrubbingSystems havebeen usedeffectively toremove a widerange of airpollutants formany industrialand municipalapplications

worldwide.


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6,000 ACFM Two-Stage Scrubbing System, steel construction with adjustable Venturi folby Packed Bed Scrubber to treat exhaust fromame lamination process

20,000 CFM Multi-Stage Scrubbing System for solid waste incineration process. (From right):Ceramic-lined inlet duct, rapid water quench, adjustable Venturi Scrubber, liquid claricationtanks, Packed Bed Scrubber, and Carbon Adsorber.

1,000 CFM Scrubbing System to remove limdust from a chemical manufacturing process.(From left): Ejector Venturi, liquid claricatiotank, high energy Venturi Scrubber, and cyclo separator. The unit was designed to achieve 9efficiency on 0.5 micron particles.

15,000 CFM Scrubbing System to condense andreclaim vaporized greaseand remove hydrocarbonfumes from a chemicalmanufacturing process.The system includesa Dual Throat Venturi Scrubber with dragconveyor, Oil RecoveryUnit, and Packed Bed Scrubber for odor control.

FPO

Oil Recovery Unit (Belt Skimmer) continuallyrecovers condensed grease from scrubbing process


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Worldwide Leader in Mist andDust Collection Equipment

Monroe Environmental has been the premiersupplier of Mist and Dust Collectors for over 40years. The largest manufacturing companies inthe world have routinely looked to Monroe tosolve their most challenging in-plant air qualityproblems, and there are several reasons why theykeep coming back to Monroe for their mist and dustcollection needs.

The Highest Quality CollectorsAvailable in the Industry

We know that every company, every plant,and every process is different. Thats why Monroedesigns and builds Mist and Dust Collectors tomeet the specic standards of your unique plant.You provide the standards that you would like yourequipment built to, then we provide a unit thatmeets those standards at a cost comparable tocompetitive off-the -shelf units. Monroe has beenthe leader in mist and dust collection for over 40years. Our customers, our repeat business, and theperformance of our Collectors all testify to that fact.

If you have an under-performing mist collectorthat was provided by another company, we canhelp. We know the competition inside and out,and we can evaluate your system and make

recommendations to get the most out of yourexisting equipment. The leaders of the machiningworld consistently look to Monroe Environmentalto x the problems created by other, lower-qualitymist collectors. We frequently repair and rehabilitacompetitive mist collectors for our customers toachieve optimal performance.

Dont be fooled by the competition nocompany in the world can provide a collectorthat will outperform the Monroe Oil MistCollector.

Mist and Dust Collection

The Monroe Oil Mist Collector A Machinists Best Friend

No machining operation is too small to benet fromthe quality, craftsmanship, and reliability of a MonroeMist Collector.

No machining operation is large enough to gobeyond the scope of what Monroe Environmental iscapable of supplying.

No other mist collector can compare in terms ofperformance, reliability, and quality over the long term.

Assembly of 37 Spiral Tube Oil Mist Collectors for an aengine and transmission machining operation

8,000 CFM Oil Mist Collector to lter parts washerat an automotive manufacturing facility

1,500 CFM Spiral Tube Mist Collector for precisionmachining operation


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Wet and Dry Dust CollectionMonroe has the expertise to recommend, design,

and manufacture a system capable of collectingand ltering many types of wet, dry, and explosivedusts as well as long, stringy solids generated by avariety of industrial manufacturing operations.

The unique, self-contained designs of theMonroe Cartridge Dust Collector and Dual ThroatVenturi Scrubber (Wet Type Dust Collector) allowfor recovery and disposal of collected particulatewith minimal maintenance over the long term.

Free standing145 ft. tall steel discharge stack for ahydrocarbonremoval systemat a steel mill

Tapered ductwork system with individual source hoodsfor multiple Oil Mist Collectors on a high productionmachining line

Custom designed ductwork system with supports forrecirculating climate-controlled clean air after ltrationthrough a 30,000 CFM Oil Mist Collector

9,600 CFM Dual Throat Venturi Scrubber for removal andrecovery of y ash from the exhaust of a wood red boiler

Left:5,000 CFM Cartridge Dust Collector to capture exhaustfrom CNC plasma cutting operation

Ductwork DesignMonroe offers a variety of ductwork designs and congurations depending on

the application, plant layout, and other site specic requirements. Plenum or tapered systems Dampers and louvers Discharge and no-loss rain stacks

Capture hoods and enclosures Custom and standard designs Single unit ducts or complete systems


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Dry Dust CollectorsCartridge Dust Collectors

Monroe Dry Dust Collectors, with reverse pulse

cleaning of cartridges during operation, providecontinuous collection and removal of airborneparticulate without shutdown. Long life pleated cartridge lters Applications up to 450F Easy to install and remove cartridges via pull-out

racks when replacement is necessary Efficiencies to 99.9+% Capacities from 500 to 50,000 CFM AMCA rated fans on the outlet side of the

collector Integral pressure gauges indicate lter

performance Variety of removal congurations available

Monroe also has the capability to design andbuild custom baghouse dust collection units whenapplicable.

Top Performance with OptimumFilter Cleaning

The Monroe Cartridge Dust Collectors moduladesign incorporates high efficiency, pleated fabriccartridge lters to achieve maximum lter surfacearea in a relatively small housing. The cartridgesin the Monroe collector are mounted in a verticalposition to provide continuous high volume collec-tion and removal of airborne dust and fumes. This

assures that when the collected dust is pulsed fromthe cartridges, it falls to the bottom of the collector

In competitor units with horizontal cartridges,dust pulsed from the above cartridges falls onto thecartridges below. This reduces ltration capabilityand requires additional maintenance for rotatingcartridges problems avoided with a Monroe unit.

Custom congurations, including ceiling or roof designs,are available where a standard collector cannot be used.30,000 CFM Dust Collector with multiple pyramid hoppersand screw conveyor options shown.

The cartridgesin the Monroecollector aremounted in avertical position

to providecontinuous highvolume collectionand removal ofairborne dust.

Vertically mounted, pleated fabric lters ensure higefficiencies for both dust collection and lter cleani

(1) 500 CFM and (2) 1,500 CFM Cartridge Dust Co

welding and wire brush deburring at an automotive


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CartridgeFilters

AirInlet

Clean AirDischarge

OptionalRotary

Air Locks

15,000 CFM Cartridge Dust Collector with rotary air lock, explosion panel, and oor mounted fan options

OptionalRotaryAir Lock

CartridgeFilters

AirOutlet

AirInlet

6,000 CFM Cartridge Dust Collector with inlet duct and storage drumexhausting a sandblasting and paint spraying operation

Cartridge Dust Collector Congurations


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Self-Contained, Single UnitDesign

Monroe Oil Mist Collectors are designed tocollect and remove airborne oil mist, smoke, andsub-micron vapors generated by operations suchas high production machining and cold forming.It is a multiple stage collector that has provencapabilities exceeding 99% efficiency on manyinstallations. After installation of a Monroe Oil MistCollector, high production machining areas usingwater soluble, synthetic, or mineral coolants candischarge clean, ltered air back into the work area,signicantly reducing climate control costs.

Features Oil, mist, smoke, and vapor removal Efficiencies up to 99.9% on 0.3 micron Capacities from 500 to 80,000 CFM Low energy requirement Continuous draining during operation Low maintenance An AMCA rated fan on the outlet side of the

collector Rubber isolation fan connection and sound

attenuators for quiet operation

Monroe isable to provideequipmentand services tomeet in-plantlevel criteria of0.5mg/m 3 orless.

Spiral TubeTwo stage collector uses spiral tubes to provide a high level of mistagglomeration and removal without using lters. Centrifugal forceand impaction provide the mechanism for primary oil mist removal.

Oil Mist Collectors

Removable Spiral Tube withring gasket at top

Tuberemoval

Right:18,000 CFM Spiral Tube Oil Mist Collectorat an automotive engine assembly plant

1,000 CFM Spiral Tube Oil Mist Collector, stainless steel construction to ltermist from a washer at afood processing facility

SpiralTubes

Air InletDirty Air/Oil In

Spiral Tubes

Oil laden air is drawndown the spiral

Oil mist is propelled bycentrifugal force to theouter tube wall

Clean air is drawn upthrough the inner tube

Separated oil dropsto the collector bottomand is discharged

Clean Air Out

OptionalHEPA Filters

12,400 CFM Spiral Tube Oil Mist Collector


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1,000 CFM CompactOil Mist Collector

OptionalHEPA

Filters

FiberglassFilters

CoalescingScreenFilters

Air Inlet

Oil Drain

Clean AirDischarge

Multi-Stage Multiple stage collector that has proven capabilities exceeding99% efficiency on many installations. Includes drop-outchamber, separator mesh elements, and berglass lters.

Design LeadershipMonroe Environmental Oil Mist Collectors, with

longer operating cycles and higher efficiencies,outperform all other collectors. Because of slowerinternal velocities through the collector, mediareplacement and maintenance labor costs arereduced. Collected oil mist and solids are continu-ously drained from the media without shut-down,signicantly prolonging lter life and loweringoverall operating costs. Monroe can integrate newunits into existing ductwork and ventilation systemsor design and furnish new ductwork depending oncustomer requirements.

HEPA Type FiltersMonroe Oil Mist Collectors are available with

specially constructed HEPA type berglass ltercartridges as the optional nal lter system. Theselters are normally supplied with a 95% efficiencyrating at 0.3 micron. These lters have a long servicelife, normally 4,500 hours or more, because themajority of contaminants are removed during thepreceding stages and are continuously drained fromthe unit.

Air processed by a Monroe Oil Mist Collectormeets air quality standards for in-plant discharge aswell as outside exhaust. Discharging clean, lteredair back into the work area can signicantly reduceclimate control costs.

The Test:

A major Americanautomotive manufaturer commissionedthe University of NoCarolina to performefficiency testing onvarious Oil Mist Cofor possible use in tmachining facilitiesfollowing quote is fthe ndings at the csion of this test peri

The Monroe ThreeCollector removed vall mist droplets of MOil, Soluble Oil and Synthetic Fluid to thof our ability to detethem. Department ofEnvironmental Sciencesand Engineering

University of North Carat Chapel Hill

7,000 CFM Multi-Stage Oil Mist Collector during nalassembly at Monroe shop

15,000 CFM Multi-Stage Oil Mist Collector


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Air Gas Cleaning&Odor Control-Monroe Environmental

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