Device for collection of particulates from FLUE gases

Abstract

A device 100 for the collection of particulates from flue gases, designed to enhance air quality by capturing and removing particulate matter from exhaust gases The device features an inlet duct that receives flue gases containing particulates; and a rotor positioned downstream of the inlet, equipped with mesh filter panels that capture particulates as the gases pass through. The rotor is connected to the inlet and outlet duct via transition hoods and has four distinct zones, including a capturing zone for particulate collection, a cleaning zone where particulates are dislodged by air nozzles, a gas exit zone for releasing cleaned gases, and an idle zone for rotor rotation without active filtration. Beneath the rotor, a hopper collects the dislodged particulates being discharged through a rotary airlock valve, to prevent air ingress.

Description

[0001] “DEVICE FOR COLLECTION OF PARTICULATES FROM FLUE

[0002] GASES”

[0003] FIELD OF THE INVENTION:

[0004] The present invention relates to a device for collection of particulates from flue gases and more particularly to a device for collection of particulates from flue gases as a pollution control device that captures and collects particulates / ash particles from the flue gases coming from combustion of fuels or hot gases / air from any process plants such as Boilers, Steel Plants, Cement Plants etc., and ensures cleaner gases / air.

[0005] BACKGROUND OF THE INVENTION:

[0006] Particulate matter (PM) consists of a complex mixture of extremely small particles and liquid droplets suspended in gases emitted from various industrial processes. These processes include, but are not limited to, boilers, combustion systems, and the production activities in steel, cement, metals, chemical, and pharmaceutical industries. The presence of PM in exhaust gases poses significant health risks to humans, leading to respiratory and cardiovascular diseases. Furthermore, PM adversely affects agriculture by impairing plant growth and contaminating soil, and it also deteriorates the quality of water bodies by the deposition of harmful substances. Given these detrimental impacts, it is important to capture and remove particulate matter from exhaust gases before they are released into the atmosphere. A Dust Collector is an essential system designed to enhance the quality of air emitted from industrial and commercial operations by extracting dust and other contaminants from air and gases. This extraction process occurs before the gases are discharged, thereby ensuring compliance with environmental regulations and safeguarding public health.

[0007] Dust collectors can be constructed as single-unit devices or as assemblies comprising multiple components that work together to separate particulate matter from process gas / air. They function as air pollution control devices, pivotal in maintaining or improving air quality within industrial and commercial environments. Various types of dust collecting equipment have been developed and disclosed in prior art, including Fabric Filter Baghouses utilizing fabric filter bags to capture dust particles through surface filtration, Inertial Separators (Mechanical Cyclones) that employ centrifugal forces to separate particulate matter from gas streams, Cartridge Collectors utilizing pleated filter cartridges to provide a large surface area for particulate capture, wet scrubbers using liquid to wash dust particles out of gas streams, Electrostatic Precipitators applying electric charges to particles in a gas stream, causing them to adhere to collector plates.

[0008] Despite these technologies electrostatic precipitators (ESPs) are associated with significant safety risks, including the potential for fatal accidents, which can result in the loss of human life. Wet scrubbers, while effective, require substantial quantities of water, leading to challenges in slurry ash handling and increased operational costs. Moreover, both ESPs and wet scrubbers demand a high voltage working environment and incur considerable maintenance expenses. These systems often exhibit uncontrolled emission levels and are not environmentally sustainable, presenting numerous drawbacks that limit their effectiveness and practicality.

[0009] The Chinese Patent Application CN108855621A to Liu Yingjian et. al. discloses an electrostatic dust collector manufactured with the machining method of the electrostatic dust collector. The electrostatic precipitator adopts a multi-layer double-helix complex type structure.

[0010] The GB Patent Application GB1523142A to Pilat M J discloses an electrostatic wet scrubber and collector assembly, wherein a surface area or volume of fine water spray droplets is used in place of respective collector plates of an electrostatic precipitator, thereby the oppositely charged spray interacts with the charged particles to precipitate them from the gas stream.

[0011] The Japanese Patent Application JP2015178084A to Tanaka Shinsuke et al. discloses a wet type of dust collector capable of purifying exhaust gas by separating exhausted particulate matter (PM) from the exhaust gas. The particulate matter (PM) is separated from the exhaust gas by dispersing bubbles which are formed by discharging the exhaust gas while rotating the diffuser tube and dispersing air bubbles in the liquid.

[0012] The electrostatic precipitators (ESP) are prone to fatal accidents and causes loss of human life, whereas wet scrubbers require huge quantity of water and lead to difficult slurry ash handling. Furthermore, the dust collectors require a high voltage working environment, huge maintenance costs, uncontrolled emission level and are not environmentally friendly. Thus, the dust collectors known in the art have several drawbacks. Therefore, there is need of an improved particulate collector that eliminates the existing high voltage and dusty environmental dust collection and equipment. There is also a need for equipment that is economical to manufacture, ensures human safety and durable in use.

[0013] SUMMARY OF THE INVENTION:

[0014] The present invention discloses a device 100 for the collection of particulates from flue gases. The device 100 for the collection of particulates from flue gases of the present invention includes an inlet duct (108) configured to receive flue gases with particulates; a rotor (112) is positioned downstream of the inlet duct (108) and rotatably mounted about a central shaft. The rotor (112) includes a plurality of mesh filter panels (216) disposed along a periphery to capture particulates from the flue gases. The device 100 further includes a first transition hood (120), a second transition hood (124), a hopper (136), a rotary airlock valve (RAV) (140), a series of air nozzles (228) and a plurality of gas zones. The first transition hood (120) is connected through the inlet duct (108) with the rotor (112) along an arcuate bottom end. The second transition hood (124) is connected with the rotor (112) through an outlet duct (116) along an arcuate bottom end that allows cleaned flue gases to exit through the device 100. The hopper (136) is positioned beneath the rotor (112) to collect the particulates dislodged from the mesh filter panels (216). The rotary airlock valve (RAV) (140) is connected to the bottom of the hopper (136), and is configured to collect discharge particulates and prevent air ingress into the device (100). A series of air nozzles (228) is mounted within the rotor (112), configured to blow air onto the mesh filter panels (216) to dislodge captured particulates into the hopper (136). The plurality of gas zones includes four zones, such as a first capturing zone, a second cleaning zone, a third gas exit zone, and a fourth an idle zone. The capturing zone captures the particulates, the cleaning zone dislodges the particulates through the air nozzles (228), the gas exit zone allows cleaned gases to exit, and the idle zone allows the rotor (112) to rotate without active filtration.

[0015] The rotor (112) in accordance with the present invention rotates at a speed between (2 to 5) revolutions per minute. The air nozzles (228) are positioned at an angle of 30 to 45 degrees relative to a vertical axis of the rotor (112) so as to optimise the blowing force to clean the mesh filter panels (216). The mesh filter panels (216) are made up of stainless steel with a mesh size of 40 to 70 microns and are removably secured to the rotor (112) for easy replacement.

[0016] The rotary airlock valve (RAV) (140) is equipped with a casing that ensures airtight operation, prevents loss of draft pressure, and maintains the performance of the device. The structural support frame (104) elevates the device to an optimal height and ensures alignment with the flue gas inlet from a boiler or process plant.

[0017] Further, the first transition hood (120) and the second transition hood (124) are connected to the rotor (112) via expansion bellows (144), which allows thermal expansion and contraction without compromising the integrity of the connections. The hopper (136) is dimensioned to align with the periphery of the rotor (112), and the transition hoods (120 and 124) provide an efficient pathway for the collection of dislodged particulates. Further, the rotor (112) includes a cylindrical cage structure. The body of the rotor (112) is defined by an assembly of horizontal flat stiffeners (208) and circular rings (204) for enhanced structural stability. The air nozzles (228) are connected to three independent air headers (220A, 220B, and 220C) within the rotor (112); each header is supplied by a main air header (220) through intermediate connecting pipes (236) to ensure uniform air pressure across all nozzles. The rotary airlock valve (RAV) (140) is driven by a gearbox, connected to a motor, and has a plurality of flanges that rotate to discharge collected particulates and maintain an airtight seal to prevent air ingress.

[0018] Now, a method for collecting particulates from flue gases using the device 100 in accordance with the present invention is described. The method includes receiving a flue gas having particulates through an inlet duct (108) into a rotating rotor (112) equipped with mesh filter panels (216). The method further includes capturing the particulates on the mesh filter panels (216) as the flue gases pass through the rotor (112). Further, the rotor (112) rotates to move the captured particulates from the capturing zone to the cleaning zone.

[0019] The captured particulates are dislodged from the mesh filter panels (216) using air jets from air nozzles (228) positioned within the rotor (112). The dislodged particulates are then collected in a hopper (136) positioned beneath the rotor (112). Finally, the collected particulates are discharge from the hopper (136) through a rotary airlock valve (RAV) (140) to prevent air ingression of the atmospheric air into the device 100 and allowing the cleaned flue gases to exit the device through an outlet duct (116). Also, the rotor (112) is rotated at a speed between 2 and 5 revolutions per minute to ensure continuous and efficient capture and removal of particulates from the flue gases.

[0020] BRIEF DESCRIPTION OF DRAWINGS:

[0021] The objectives and advantages of the present invention will become apparent from the following description read in accordance with the accompanying drawings wherein,

[0022] FIG. 1 shows a perspective view of the device 100 for collection of particulates from flue gases for collecting particulate matter from exhaust gas in accordance with the present invention;

[0023] FIG. 2 shows a front elevated view of the device 100 for collection of particulates from flue gases of FIG. 1 ;

[0024] FIG. 3 shows a front view of the device 100 for collection of particulates from flue gases of FIG. 1;

[0025] FIG. 4 shows a schematic representation of the rotor of the device 100 of FIG. 1;

[0026] FIG. 4A shows a cross-sectional enlarged view showing an air distribution header, air nozzles, and a mesh filter panel of the rotor of the device 100 of FIG. 1;

[0027] FIG. 4B shows a cross-sectional view showing a flat strip with a nut-bolt of the rotor of the device 100 of FIG. 1;

[0028] FIG. 4C shows a cross-sectional view of a mesh filter panel of the rotor of the device 100 of FIG. 1; FIG. 4D shows a cross-sectional view of a mesh filter panel including a stud and nut, an end support plate, and a mesh support shell of the rotor of the device 100 of FIG. 1;

[0029] FIG. 5 is a top perspective view of the rotor of the device 100 of FIG. 1 showing distribution of air though connecting pipe; and

[0030] FIG. 6 is a process flow diagram explaining the flow of the flu gases in the device 100 of FIG. 1.

[0031] DESCRIPTION OF THE INVENTION:

[0032] References in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0033] References in the specification to “preferred embodiment” means that a particular feature, structure, characteristic, or function described in detail thereby omitting known constructions and functions for clear description of the present invention.

[0034] The foregoing description of specific embodiments of the present invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed and obviously many modifications and variations are possible in light of the above teaching. Referring to FIG. 1, a device for collection of particulates from flue gases 100 (hereinafter referred to as “device 100”) is shown. The device for collection of particulates from flue gases 100 is preferably securely installed on a robust platform having stability and durability. This platform includes a steel structural frame 104 that is supported by steel columns and tie beams, ensuring the entire assembly remains firm and reliable during operation. The platform is preferably constructed using a steel grating, providing a sturdy and accessible surface. This grating is supported by a series of pillars firmly anchored to the ground, offering a stable foundation for the device 100. The arrangement of these platforms around the device 100 facilitates easy access and maintenance, ensuring that the device 100 is serviced efficiently when needed.

[0035] It is noted that, in this one embodiment, the height of the platform is an important consideration, as it depends on the alignment with the column centerline and the gas inlet duct from the boiler or process plant. The platform elevates the device 100 to an optimal height, which in this case is preferably 15 meters. This height ensures proper alignment and efficient operation of the gas inlet duct, allowing the device 100 to effectively capture and collect particulate matter from the exhaust gases.

[0036] The device 100 receives flue gas from an outlet of an air preheater in case of fired boiler, or economiser, or a condensate preheater in case of unfired waste heat boiler. These flue gases include burnt fuel in the form of ash particles of various sizes. The device 100 captures and collects particulates / ash particles from the flue gases coming out from the combustion of fuels, hot gases / air from any process plants such as Boilers, Steel Plants, Cement Plants, Metallurgical Plants etc. The device 100 separates the ash / dust particles from the flue gases that are received in a hopper. The ash / dust particles that are collected in a hopper are continuously discharged to an ash / dust conveying / handling system through a rotary airlock valve (RAV) positioned at the discharge point of the hopper. The RAV ensures no atmospheric air ingress to the device 100.

[0037] Now, the device for collection of particulates from flue gases 100 in accordance with a preferred embodiment of the present invention is described. The device 100 includes an inlet duct 108, a rotor 112, and an outlet duct 116. A first transition hood 120 is positioned between the inlet 108 and the rotor 112. Similarly, a second transition hood 124 is positioned between the rotor 112 and the outlet 116.

[0038] The inlet duct 108 is connected with the rotor 112 through a first transition hood 120 such that an inlet bellows is positioned between the first transition hood 120 and the inlet duct 108. The outlet duct 116 is connected with the rotor 112 through a second transition hood 124 such that an outlet bellows is positioned between the second transition hood 124 and the outlet duct 116. In this one embodiment, the inlet duct 108 as well as the outlet duct 116 are rectangular in shape with dimensions of 2 m x 2 m. In other embodiments, the inlet duct 108 and outlet duct 116 are of circular or oval shape. The first transition hood 120 and second transition hood 124 are of trapezoidal shape. The top portion of the hoods 120, 124 are of planar cross section, and the bottom portion is arcuate in shape.

[0039] The first transition hood 120 and the second transition hood 124 are connected by an arcuate plate that defines a top casing 128 of the rotor 112. The top casing 128 is an arcuate shaped body. The rotor 112 is positioned below the top casing 128 and a rotor shaft 132 is positioned approximately centrally in the rotor 112. In this one embodiment, the pair of circular side casings 128 has an arc radius of around 2.8 meters relative to a centre line that coincides with the rotor shaft 132.

[0040] In accordance with the present invention, a hopper 136 is positioned approximately below the rotor 112. A rotary airlock valve (RAV) 140 is positioned at the bottom of the hopper 136. It is secured to the bottom of the hopper 136 by welding or bolting. The RAV 140 includes a plurality of flanges that are rotated by the gearbox that is engaged with a motor. The RAV 140 includes a casing around the components of the RAV 140 that makes the RAV 140 airtight.

[0041] The RAV 140 releases air and ash and avoids any air ingression of the atmospheric air in the device 100. It is noted that if the atmospheric air is received in the device 100, that may cause loss of the draft, i.e., a pressure drop that may unbalance the device 100 performance. The convey ing / handling system, hereinafter referred to as the conveying system, is positioned below the RAV 140. The conveying system transfers the ash received from the RAV 140 to the common ash handling system of the respective boiler.

[0042] Referring to FIG. 3, a front view of the device for collection of particulates from flue gases 100 is shown. Accordingly, the inlet duct 108 receives the flue gases to be filtered in the device 100. The inlet duct 108 is circular or rectangular in shape and made up of mild steel. The size of the inlet duct 108 varies according to the gas / air flow and has a thickness of 6 mm. An expansion bellow 144 is connected between the inlet duct 108 and the first transition hood 120, the outlet duct 116, and the second transition hood 124. The expansion below 144 manages thermal expansions. The expansion bellow 144 is made of two types of materials metallic or non-metallic. The expansion bellow 144 consists of flow plates inside the bellows that ensure no accumulation of ash or dust inside the bellow volutes.

[0043] The hopper 136 is securely installed on the structural support frame 104 such that a top end of the hopper 136 is aligned with the periphery of the rotor 112 and ends of the first transition hood 120 and the second transition hood 124, and a bottom end of the hopper 136 is connected with the rotary airlock valve (RAV) 140. The height of the hopper 136 depends upon the gas inlet duct elevation and the valley angle required. The outlet duct 116 is positioned exactly opposite the inlet duct 108. The outlet duct 116 is circular or rectangular in shape and made up of mild steel. The size of the outlet duct 116 varies according to the gas or air flow and has a thickness of 6 mm. The outlet duct 116 is connected to the second transition hood 124 with the expansion bellow 144.

[0044] The rotor 112 is housed between the first transition hood 120 and the second transition hood 124. The bottom side of the rotor 112 is aligned with the first transition hood 120, the second transition hood 124, the pair of circular side casings 128 and the hopper 136. The first transition hood 120 and the second transition hood 124 are connected to the rotor 112 through nut bolting or welding.

[0045] The pair of circular side casing 128 is positioned on both sides as end plate for closing the rotor 112. The rotary airlock valve (RAV) 140 is fitted at the discharge point of the hopper 136. The RAV 140 ensures continuous removal of particulates from the hopper 136 and at the same time ensures no air ingress to the system.

[0046] Referring to FIG’s 4, 4A, 4B, 4C, 4D and 5, the rotor 112 in accordance with the present invention is described. The rotor 112 is an approximately cylinder structure made of material, for example, stainless steel material. The rotor 112 includes a pair of end plates that are opposed positioned on the rotor body. The rotor body includes a cylindrical cage of stainless- steel material. Accordingly, the rotor body has a plurality of horizontal flats and a plurality of circular flats or circular rings. As per the present invention, the body of the rotor 112 is defined by the assembly of a horizontal flat stiffeners and a circular ring. The assembly of the structure that resembles a cylindrical cage. In accordance with the present invention, a cylindrical filter element is securely positioned on the inner periphery of the rotor 112 by connectors like nuts and bolts, and a filter element is defined by a sheet, for example, a stainless steel with 1 mm thickness.

[0047] The rotor 112 includes a circular ring 204, a horizontal flat stiffeners 208, a stud 212, a mesh filter panel 216, a main air header 220, an three air headers 220A, 220B, and 220C, an air nozzles 228, and a flat strip with a nut-bolt 232. Further, the rotor 112 includes a connecting pipes 236 and a hollow shaft 240. In addition, the mesh filter panel 216 includes a stud and nut 304, an end support plate 308 and a mesh support shell 312.

[0048] Accordingly, the rotor 112 is made up of the circular ring 204 and the horizontal stiffeners 208 that have closed grids for structural stability and a frame for fixing the mesh filter panels 216. The studs 212 are welded on the grid frame at an optimum distance or pitch to hold the mesh filter panels 216 in position with the flat strip with nut bolts 232. The studs 212 firmly hold the mesh filter panels 216 on either side. The stud 212 material is selected to withstand the tension load from curved mesh filter panels 216, and the length is optimum to avoid fouling with the air nozzles 228 on the main air distribution header 220.

[0049] Inside the rotor 112, the air nozzles 228 are fitted on the three air headers 220A, 220B, and 220C, positioned at an angle of 30 - 45 degrees from the vertically downward center one. Each header is fitted with the air nozzles 228, focussing downwards at a pitch of 120 mm. The tips of the air nozzles 228 are as close to the mesh filter panels 216 surfaces as possible for good blowing force and effective cleaning. The gap between the tip of the air nozzles 228 and the mesh filter panels 216 in the rotor 112 is based on the ovality of the rotor 112, so that air nozzles 228 are not fouling with the rotor 112 when the rotor 112 rotates.

[0050] All the three air headers, 220A, 220B, and 220C, run along the entire length of the rotor 112. The number of the air nozzles 228 is based on the length of the rotor / header. These three rows of the air nozzles 228 are specially designed considering the blowing force required to blow away the ash and dust from the mesh filter panels 216. Further, the arrows Al, A2, and A3 in FIG. 5 show the direction of the air flow through the rotor 112 and also through the device 100.

[0051] It is noted, however, that the amount of air required for cleaning the mesh filter panel 216 is determined in accordance with the air consumption of the selected blowing force. The air headers 220A, 220B, and 220C, fitted with the air nozzles 228, are connected to the main air header 220 supply by intermediate air connecting pipes 236 at multiple locations along the length of the headers for uniform air pressure. Air pressure in all three air headers 220A, 220B, and 220C is controlled by independent valves fitted on the connecting pipes 236 from the main air header 220 outside the rotor 112. The main air header 220 is fitted with a pressure gauge to measure the air pressure at the air nozzles 228.

[0052] From the main air header 220, in this one embodiment, three connecting pipes 236 are positioned as connections to the three independent air headers 220A, 220B, and 220C inside the center of the hollow shaft 240 of the rotor 112. The hollow shaft 240 is fixed and rigidly mounted on both ends of the rotor 112, outside the gas path. The rotor 112 rotates freely over this hollow shaft 240, with a bearing connection on either end. The rotor 112 is supported on either end with a bearing to facilitate its free rotation. The rotor 112 is coupled to a gearbox driven by a chain. In this embodiment, the rotor 112 had a diameter of about 5.5 meters.

[0053] Referring to FIG. 6, a process flow of the flu gases in the device for collection of particulates from flue gases 100 in accordance with the present invention is described. The device 100 receives flue gas from an outlet of an air preheater of an existing boiler or an economiser / condenser preheater in case of a waste heat boiler or any other boiler, through the inlet duct 108. The inlet duct 108 ensures gas or air with particulate matter passes through the rotor 112 through the first transition hood 120. The rotor 112 rotates at a speed between 2 and 5 revolutions per minute. As the rotor 124 rotates, the types of ash and dust particulates that are captured on the surfaces of the mesh filter panel 216 come down to the hopper 136 in a downward direction. The mesh filter panel 216 is removable and replaceable by the other mesh filter panel 216 by removing the nut-bolts manually.

[0054] As the particles are captured, they are cleaned by blowing air through the air nozzles 228. Further, the dust or ash particles are dropped down into the hopper 136 and are passed through the settling chamber, and, pass through the second transition hood 124 and leave treated flue gas through the outlet duct 116. The treated flue gas is preferably clean flue gas achieved after removal of predefined dust particles from the flue gases received in the device 100. It is noted that the treated flue gas has had particulate matter removed through the filtration method and device 100 of the present invention, making it less harmful to the environment when released into the atmosphere.

[0055] Additionally, the mesh filter panel 216 is removable and replaceable with another approximately identical mesh as per the requirement of the appropriate particle size in order to change the particle size that is to be filtered.

[0056] Now, the working of the device for collection of particulates from flue gases 100 in accordance with the preferred embodiment of the present invention is described. The device 100 receives flue gas from an outlet of an air preheater of an existing boiler or, an economiser / condenser preheater in case of waste heat boiler, through the inlet duct 108. The inlet duct 108 ensures gas / air with particulate matter to pass through the 100°- 120° segment of the rotor 112, in horizontal plane in one direction. The flue gas / hot air with particulates enters the rotor 112 through first transition hood 120, the transition duct ensures uniform flow of gas through the rotor 112 surfaces. The included angle of transition varies between 90-120°. Further, the rotor 112 defines four zones, such as a first capturing zone, a second cleaning zone, a third gas exit zone, and a fourth idle zone. The first capturing zone is approximately 90 to 120 degrees of the rotor 112. In this zone, flue gas with ash or dust particulates flows through the mesh filter panels 216, leaving the ash particles settled or captured over the outer surface of the mesh filter panels 216. In this zone, the dust particles are categorised into two categories, such as captured particles and allowable particles. The captured particles are captured on the outer surface of the rotor 112, whereas the allowable gases are directed by ID fans of the device 100 to the outer portion of the rotor 112, i.e., already cleaned, and thereby the allowable gases are released to the chimney of the boiler on which the device is positioned.

[0057] The second cleaning zone is approximately 90 to 120 degrees of the rotor 112. In this, the three air headers 220A, 220B, and 220C with the air nozzles 228 along the length of the rotor 112 are located perpendicular to the filter surfaces. The first air header 220A is at the start of the cleaning zone; the second header 220B is in the middle, that is vertically down at the vertical central axis of the rotor 112; and the third header 220C is at the end of the cleaning zone. The hopper 136 is mounted below this cleaning zone for collecting the ash and dust blown off of the surfaces of the mesh filter panels 216 by these three rows of air nozzle 228.

[0058] The third gas exit zone is almost equal to the cross-section of the capturing zone, i.e., 90 to 120 degrees of the rotor 112, as this zone is in line with the capturing zone, 180 degrees apart. The clean gas, after leaving the particles on the mesh filter panels 216, travels through the inner space of the rotor 112 and exits through this zone.

[0059] The fourth idle zone is the top zone of the rotor 112, where there are no operations occurring, making this the inactive zone. The rotor 112 with the cleaned mesh filter panel 216 passes through this section to the next capturing zone. The enclosure of this section is very closely positioned to avoid any gas bypassing through this section.

[0060] The flue gas carrying ash particles leaves the four zones of the rotor 112 and accumulates on the surfaces of the mesh filter panels 216 that are installed around the rotor 112. The clean gas passes through the mesh filter panels 216 and exits on the opposite side of the rotor 112. The SS mesh panels used as filtering elements have a size of 40 -70 micron.

[0061] The type of application determines the opening or mesh number of the mesh filtering panels 216, since the type of plant and combustion process affect the size of the ash particles. The rotor 112 rotates at a speed between 2 and 5 revolutions per minute. The speed of the rotor 112 depends on the flow rate of flue gas, ash or dust concentration, type of combustion, type of process, and type of process downstream. The speed is selected in such a way that adequate cleaned surfaces are available for capturing and filtering particulates from the incoming gas stream.

[0062] After that, as the rotor 112 rotates, the types of ash and dust particulates that are captured on the surfaces of the filter element come down to the hopper 136 zone. The three rows of air nozzles 228 are where the dislodging zone is reached by the rotor 112 with the dust layer. The dust from the filtering element on the rotor 112 is expelled by the first set of air nozzles. Furthermore, by rotating the rotor 112, the second set of air nozzles in the downward direction and the third set of air nozzles at the beginning of the gas escape zone ensure complete cleaning of the filtration unit.

[0063] The air jets from the air nozzles 228 clean / dedust the first type of ash particulates from the filter elements and direct the dust / ash to the hopper 136 fitted at the bottom equipment. The hopper 136 collects ash / dust blown out of the filtering elements by the air jets from air nozzles 228. The Rotary Airlock Valve (RAV) 140 fitted at the discharge mouth of the hopper 136 ensures dust evacuation from the RPC device 100 without allowing any air ingress into RPC device 100 due to negative pressure (suction) by the ID Fan. The outlet duct 116 allows the gas / air to pass out of the rotor 112 through 90°- 120° segment, in horizontal plane exactly opposite to the gas inlet duct 108.

[0064] In accordance with the present invention, the arc length of the rotor 112 surface is the focus of the flue gases, that include ash particles of different sizes. The arc length that corresponds to 90-110 degrees is dependent upon the rotor 112 diameter. The diameter and length of the rotor 112 determine the total surface area that is available to be used to capture ash. The amount of flue gas and the concentration of ash and particles in the flue gas are used to determine the diameter and length of the rotor 112.

[0065] In cases of increased flue gas quantity, the area required for the gas to pass through is higher; hence, either the diameter of the rotor 112 or the length of the rotor 112 needs to be increased. Similarly, in cases of increased dust concentration, the clean area required for capturing the ash shall be greater, hence the diameter or length of the rotor needs to be increased. A marginal increase in flow or dust concentration can be addressed by varying the speed of the rotor within the range of 2 - 5 RPM. In accordance with the present invention, a first example of the removal of the ash from the flue gases is discussed, and also the working parameters of the device 100 for collection of particulates from flue gases in accordance with the preferred embodiment of the present invention are described in Table 1. In this case, a bagasse-fired boiler of capacity 75 tonnes per hour (TPH) was implemented, and the flu gases released from this boiler were received by the device 100. This boiler was fired for 25 days, and the device 100 operated for 25 days. The amount of flue gas that flows from the output through the duct to the rotor 112 to clean the particulates with the air pressure from the air nozzles 228 may alter these working parameters. The following observations were made as per Table 1. Table 1: The example above shows that the received flue gases had a dust content of 120 mg / Nm3, that was subsequently reduced to 42 mg / Nm3. This results in a significant reduction in the amount of dust particles released into the atmosphere accompanied by the flue gases. In accordance with the present invention, a second example of the removal of the ash from the flue gases is discussed, and also the working parameters of the device 100 for collection of particulates from flue gases in accordance with the preferred embodiment of the present invention are described in Table 2. In this case, a bagasse-fired boiler of capacity 60 tonnes per hour (TPH) was implemented, and the flu gases released from this boiler were received by the device 100. This boiler was fired for 25 days, and the device 100 operated for 25 days. The amount of flue gas that flows from the output through the duct to the rotor 112 to clean the particulates with the air pressure from the air nozzles 228 may alter these working parameters. The following observations were made as per Table 2. Table 2:

[0066] The example above shows that the received flue gases had a dust content of 120 mg / Nm3, that was subsequently reduced to 50 mg / Nm3. This results in a significant reduction in the amount of dust particles released into the atmosphere accompanied by the flue gases.

[0067] Advantageously, the device 100 for collection of particulates from flue gases provides the rotor 112 with segmented filtering elements. This ensures simple assembling and replacement of panels at a specific location. The operation of the device 100 does not require high voltage to prevent sparks or fires during operation and thus eliminates the existing high voltage / high dusty environmental dust collection methods and equipment. It also filters the ash and dust particles from the gas in a simple manner without the consumption of a huge quantity of water.

[0068] Further, the rotor 112 rotates at a very low RPM of 2-3, that ensures a longer life of the rotor 112 and benefits low maintenance costs. In the device 100, ash / dust is blown outside the gas / air path to avoid carrying over of particulates along with gas / air. Continuous capturing of particulates, blowing off, and discharging ensures clean gas, and no accumulation over the device 100 ensures human safety and durability in use. Additionally, the construction and installation of the device 100 is simple. It has low running costs and no complex or precise parts.

[0069] The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others, skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.

[0070] It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

Claims

Claims:

1. A device 100 for the collection of particulates from flue gases, comprising: an inlet duct (108) configured to receive flue gases with particulates; a rotor (112) positioned downstream of the inlet duct (108) and rotatably mounted about a central shaft, the rotor (112) including a plurality of mesh filter panels (216) disposed along a periphery to capture particulates from the flue gases; a first transition hood (120) connecting the inlet duct (108) to the rotor (112) along an arcuate bottom end; a second transition hood (124) connecting the rotor (112) to an outlet duct (116) along an arcuate bottom end, allowing cleaned flue gases to exit the device; a hopper (136) positioned beneath the rotor (112) for collecting the particulates dislodged from the mesh filter panels (216); a rotary airlock valve (RAV) (140) connected to the bottom of the hopper (136), configured to discharge collected particulates while preventing air ingress into the device (100); a series of air nozzles (228) mounted within the rotor (112), configured to blow air onto the mesh filter panels (216) to dislodge captured particulates into the hopper (136); a plurality of gas zones including four zones such as a first capturing zone, a second cleaning zone, a third gas exit zone, and a fourth an idle zone, wherein the capturing zone capturing the particulates, the cleaning zone dislodgingparticulates by the air nozzles (228), the gas exit zone allowing cleaned gases to exit, and the idle zone allowing the rotor (112) to rotate without active filtration.

2. The device 100 for the collection of particulates from flue gases of claim 1, wherein the rotor (112) rotating at a speed between (2 to 5) revolutions per minute, and the air nozzles (228) being positioned at an angle of (30 to 45) degrees relative to a vertical axis of the rotor (112) optimizing the blowing force for cleaning the mesh filter panels (216).

3. The device 100 for the collection of particulates from flue gases of claim 1, wherein the mesh filter panels (216) being made of stainless steel with a mesh size of 40 to 70 microns, and removably secured to the rotor (112) for easy replacement.

4. The device 100 for the collection of particulates from flue gases of claim 1, wherein the rotary airlock valve (RAV) (140) being equipped with a casing that ensures airtight operation, preventing loss of draft pressure and maintaining the performance of the device.

5. The device 100 for the collection of particulates from flue gases of claim 1, wherein the device 100 including a structural support frame (104) elevating the device to an optimal height, ensuring alignment with the flue gas inlet from a boiler or process plant.

6. The device 100 for the collection of particulates from flue gases of claim 1, wherein the first transition hood (120) and the second transition hood (124) being connected to the rotor (112) via expansion bellows (144), allowingfor thermal expansion and contraction without compromising the integrity of the connections.

7. The device 100 for the collection of particulates from flue gases of claim 1, wherein the hopper (136) being dimensioned to align with the periphery of the rotor (112) and the transition hoods (120, 124), providing an efficient pathway for the collection of dislodged particulates.

8. The device 100 for the collection of particulates from flue gases according to claim 1, wherein the rotor (112) including a cylindrical cage structure, and the body of the rotor (112) being defined by an assembly of horizontal flat stiffeners (208) and circular rings (204) for enhanced structural stability.

9. The device 100 for the collection of particulates from flue gases according to claim 1, wherein the air nozzles (228) being connected to three independent air headers (220A, 220B, and 220C) within the rotor (112), each header being supplied by a main air header (220) through intermediate connecting pipes (236) to ensure uniform air pressure across all nozzles.

10. The device 100 for the collection of particulates from flue gases according to claim 1, wherein the rotary airlock valve (RAV) (140) driven by a gearbox being connected to a motor, and including a plurality of flanges that rotate to discharge collected particulates while maintaining an airtight seal to prevent air ingress.

11. A method for collecting particulates from flue gases by the device 100 for collection of particulates from flue gases as claimed in Claim 1, the method comprising:a. directing flue gases containing particulates through an inlet duct (108) into a rotating rotor (112) equipped with mesh filter panels (216); b. capturing particulates on the mesh filter panels (216) as the flue gases pass through the rotor (112); c. rotating the rotor (112) to move captured particulates from a capturing zone to a cleaning zone; d. dislodging the captured particulates from the mesh filter panels (216) using air jets from air nozzles (228) positioned within the rotor (112); e. collecting the dislodged particulates in a hopper (136) positioned beneath the rotor (112); f. discharging the collected particulates from the hopper (136) through a rotary airlock valve (RAV) (140) while preventing air ingress into the device (100); and g. allowing the cleaned flue gases to exit the device through an outlet duct (116).

12. The method according to claim 11, wherein the rotor (112) being rotated at a speed between 2 and 5 revolutions per minute, ensuring continuous and efficient capture and removal of particulates from the flue gases.

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