SYSTEM FOR FINE PARTICULATE AND GASEOUS POLLUTANT REMOVAL BY METHOD OF BI-POLAR ELECTRIFIED CYCLONIC AGGLOMERATION PROCESS (BE-CAP)

Abstract

The present invention discloses a Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP), an advanced system for simultaneous removing fine particulate matter (PM2.5), Sulphur dioxide (SO2), Nitrogen oxide (NO) from industrial flue gas streams. The system includes an Electrostatic Charger Configuration (ECC) (118) that generates positive and negative electric fields, charging dust particles (108) as the flue gas (112) is divided into two sub-streams. The charged particles are then introduced into a Cyclonic Agglomeration Process (CAP) (136) or Electrified Cyclonic Agglomeration Process (e-CAP) (137) via tangential sub-stream inlet ducts (102), where cyclonic motion induces collisions, forming large dust agglomerates (109). The clean gas (104) exits through a vortex tube (103), while the agglomerated dust particles are collected in an agglomerate dust hopper (110). The system can be retrofitted for pre-treatment or post-treatment with existing technologies such as cyclones (141), electrostatic precipitators (142), or bag filters (143), ensuring compliance with stringent emission standards.

Specification

Description:A) TECHNICAL FIELD
[0001] The present invention relates to a method and system for removing particulate matter (PM2.5) from industrial flue gas streams using the Bi-Polar Electrified Cyclonic Agglomeration Process (Be-CAP). More specifically, this process utilizes electrostatic charging and cyclonic motion to increase particle collisions, resulting in the formation of larger dust agglomerates, and also simultaneously converts the gaseous pollutants sulphur di-oxides (SO2), nitrogen monoxides (NO) to higher oxides forms, which are then efficiently removed from the gas stream
B) BACKGROUND OF THE INVENTION
[0002] Industrial processes are a significant source of fine particulate emissions, including particles smaller than 2.5 microns (PM2.5). These particles pose severe environmental and health risks as they penetrate deep into the human respiratory system, contributing to diseases such as asthma, lung emphysema, and other respiratory conditions. Government regulations around the world have increasingly tightened to reduce such emissions.
[0003] Existing filtration technologies such as bag filters, cyclones, electrostatic precipitators, and wet scrubbers have demonstrated limited success in addressing the fine dust particle pollution, particularly in removing PM2.5 particles. These technologies are generally more effective for larger particles, leaving smaller particles like PM2.5 inadequately filtered.
[0004] Multiple design enhancements have been proposed to improve the performance of these systems, including chemical sorbent injection, acoustic agglomeration, and flue gas conditioning. However, these methods increase operational and capital costs, and none has consistently proven efficient for fine particle removal in practice.
[0005] Several techniques have been implemented to enhance electrostatic precipitators, such as high-frequency power supplies and moving electrodes, but these approaches have either been too expensive or yielded negligible improvements. The limitations of existing filtration technologies highlight the need for a more effective, economically feasible solution for fine particle agglomeration and removal.
[0006] Existing gas purification technologies like wet & dry based absorption techniques for gaseous pollutants specifically for sulphur di-oxides (SO2) and Nitrogen monoxide (NO) are being in current practice, but these approaches have either been separate process for absorption of both the gaseous pollutants, too expensive and also associated with operation issue.
[0007] In more specific, following general co-relations have been highlighted to understand more clearly for the development of Be-CAP with effective and economically feasible solution,
------------------------------------ (1)
----------------------------------- (2)
------------------------------------ (3)
[0008] Here in the above co-relations (1,2 and 3), m = mass of dust particle; Fc = Centrifugal force; dp = Particle diameter; Q = Electrostatic charge
[0009] From above all co-relations; mass of the particle, centrifugal force, electrostatic charge is directly proportional the particle diameter. As the particle size decreases, mass of dust particles decreases drastically thereby results in lower centrifugal force and lower electrostatic charge holding capacity. Hence, one of the best alternative techniques is to make the particle diameter bigger in size through the dry type particle agglomeration by the maximum utilization of combined centrifugal force and electrostatic charge.
[0010] Thus, there is a growing demand for a system and method that can be integrated with existing filtration systems to remove fine dust particles (PM2.5), SO2, NO efficiently while maintaining cost-effectiveness, compactness, and operational simplicity. The present invention, Be-CAP, addresses these needs.
[0011] The above-mentioned shortcomings, disadvantages and problems are addressed herein and which will be understood by reading and studying the following specification.

C) OBJECTS OF THE INVENTION
[0012] The primary object of the present invention is to provide a method and system for efficiently removing fine particulate matter (PM2.5) from industrial flue gas streams through a combination of electrostatic charging and cyclonic agglomeration.
[0013] Another object of the present invention is to achieve high collection efficiency for PM2.5 particles by increasing particle size through bi-polar electrostatic charging, making them easier to remove from the gas stream.
[0014] Yet another object of the present invention is to integrate the Bi-Polar Electrified Cyclonic Agglomeration Process (Be-CAP) with existing filtration technologies as a pre-treatment or post-treatment system to enhance overall performance.
[0015] Yet another object of the present invention is to provide a cost-effective solution that meets stringent environmental emission norms while minimizing capital and operational costs.
[0016] Another object of the present invention is to offer a modular and customizable system that can be scaled to handle various flue gas capacities, ranging from small to large industrial applications.
[0017] Yet another object of the present invention is to provide a system with a low-pressure drop, ensuring reduced energy consumption and lower operational costs for continuous industrial processes.
[0018] Yet another object of the present invention is to deliver a compact design that reduces the installation footprint, making it suitable for industries with space constraints.
[0019] Another object of the present invention is to ensure near-zero maintenance by eliminating moving parts and relying on robust construction, making the system highly durable and reliable.
[0020] Yet another object of the present invention is to enhance particle agglomeration through the combined effects of electrostatic force and cyclonic motion, thereby increasing the likelihood of particle collisions and agglomeration.
[0021] Yet another object of the present invention is to convert gaseous pollutant, in particularly sulphur di-oxide (SO2) and Nitrogen monoxide (NO) to higher oxides, thereby increasing in the water absorption.
[0022] Another object of the present invention is to provide a retrofittable solution that can easily integrate into both new and existing industrial setups without causing significant downtime or disruption to operations.
[0023] These and other objects and advantages of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.
D) SUMMARY OF THE INVENTION
[0024] The various embodiments of the present invention provide a Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP), which represents a breakthrough in air pollution control technologies by focusing on the removal of fine particulate matter (PM2.5) from industrial flue gas streams. This technology combines electrostatic charging and cyclonic agglomeration to significantly enhance the capture of fine particles, which are traditionally challenging to remove with existing systems. The invention targets PM2.5 particles, known for their harmful health effects, by causing smaller particles to agglomerate into larger ones, which can be efficiently filtered out by subsequent filtration systems.
[0025] At the core of the invention is the Electrostatic Charger Configuration (ECC), which charges dust particles with opposite polarities. Half of the dust particles in the flue gas are charged positively, while the other half are charged negatively. This step is crucial because it sets up the dust particles for agglomeration in the next stage. By leveraging electrostatic forces, the invention creates an environment where oppositely charged particles are more likely to collide and stick together, forming larger agglomerates.
[0026] Once the particles are charged, they are introduced into the Cyclonic Agglomeration Process (CAP). This process subjects the particles to cyclonic motion, which increases the likelihood of collisions between the oppositely charged particles. The cyclonic motion creates centrifugal forces that push the particles towards the outer edges of the cyclonic chamber. Combined with the electrostatic attraction between oppositely charged particles, this motion significantly increases the efficiency of agglomeration, leading to the formation of larger dust particles that are easier to capture.
[0027] One of the most significant advantages of the Be-CAP process is its ability to enhance the performance of existing filtration technologies. The invention is designed to be integrated as a pre-treatment or post-treatment process with common air pollution control systems like electrostatic precipitators, bag filters, and scrubbers. By doing so, the Be-CAP process boosts the efficiency of these systems in capturing fine particulate matter, enabling industries to meet stringent emission regulations with minimal modifications to their existing infrastructure.
[0028] The flexibility of the Be-CAP process is another key feature. It can be applied in various industrial settings where PM2.5 emissions are a concern, such as power plants, cement factories, and steel mills. The process can be easily scaled and adapted to different types of flue gas streams, making it a versatile solution for a wide range of industries. Moreover, because the Be-CAP system can be retrofitted into existing setups, it reduces the need for costly overhauls and minimizes downtime during installation.
[0029] From a technical perspective, the combination of electrostatic force of attraction and cyclonic forces is what sets this invention apart from traditional methods. In conventional systems, electrostatic precipitators and cyclonic separators operate independently, often with limited success in removing fine particles. However, by combining the strengths of both technologies, the Be-CAP process ensures that fine particles, especially those in the PM2.5 range, are effectively captured. The cyclonic motion helps overcome the limitations of electrostatic precipitators, which tend to struggle with smaller particles that have lower mass and electrostatic charge.
[0030] In terms of environmental impact, the Be-CAP process addresses one of the most pressing concerns in industrial emissions: fine particulate matter pollution. PM2.5 particles are small enough to penetrate deep into the human respiratory system, causing a range of health problems, including asthma, cardiovascular diseases, and premature death. By providing a more effective means of capturing these particles, the Be-CAP process contributes to improved air quality and public health, especially in regions where industrial emissions are a significant source of air pollution.
[0031] Another important aspect of the Be-CAP process is its potential for energy efficiency. Traditional air pollution control technologies, such as wet scrubbers and electrostatic precipitators, can be energy-intensive and costly to operate. The Be-CAP process, on the other hand, operates with minimal pressure drops and can be integrated with existing systems without significantly increasing energy consumption. This makes it a cost-effective solution for industries looking to reduce their environmental footprint while maintaining operational efficiency.
[0032] The scalability of the Be-CAP system is another factor that adds to its commercial viability. The process can be designed for different scales, from small plants to large industrial facilities, making it suitable for a wide range of applications. Its ability to handle varying flue gas compositions and particle loads ensures that it can be applied across industries with different emission profiles, from energy production to manufacturing.
[0033] Finally, the Be-CAP process aligns with the growing trend towards green technology. As governments worldwide tighten regulations on industrial emissions, there is an increasing demand for technologies that can help industries meet these regulations while minimizing environmental impact. The Be-CAP process, by enhancing the efficiency of particle removal and reducing the operational costs of existing systems, positions itself as a critical innovation in the transition towards more sustainable industrial practices.
[0034] In conclusion, the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) offers a novel and effective solution for removing fine particulate matter from industrial flue gas streams. By combining electrostatic charging and cyclonic motion, it addresses the limitations of existing technologies and provides a versatile, scalable, and energy-efficient option for industries looking to reduce their PM2.5 emissions. Its potential to improve air quality and public health, while offering commercial and operational advantages, makes it a valuable innovation in the field of air pollution control.
[0035] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating the preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

E) BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:
[0037] Figure 1 illustrates an isometric view of the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) system, featuring a single Electrostatic Charger Configuration (ECC), according to an embodiment of the invention.
[0038] Figure 2 illustrates an isometric view of the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) system with multiple Electrostatic Charger Configurations (ECCs), according to an embodiment of the invention.
[0039] Figure 3 shows a cross-sectional view of the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP), corresponding to Figures 1 and 2.
[0040] Figure 4 illustrates a top cut-away perspective isometric view depicting a distinct embodiment of the Cyclonic Agglomeration Process (CAP), according to the present invention.
[0041] Figure 5 provides a cross-sectional view of the Cyclonic Agglomeration Process (CAP), corresponding to Figure 4, showing the flue gas sub-stream inlet, large agglomerates collection, and clean gas outlet passages.
[0042] Figure 6 shows a top cut-away perspective isometric view illustrating a distinct embodiment of the Electrified Cyclonic Agglomeration Process (e-CAP) with a combined charging unit.
[0043] Figure 7 offers a cross-sectional view of the e-CAP, corresponding to Figure 6, detailing the flue gas sub-stream inlet, large agglomerates collection, and clean gas outlet passages.
[0044] Figure 8 illustrates a cross-sectional view of the Electrostatic Charger Configuration (ECC), showing the discharge-collector electrode assembly.
[0045] Figure 9 provides a cross-sectional view of the integrated discharge-collector electrode assembly.
[0046] Figure 10 depicts a schematic process flow diagram of the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) system, corresponding to Figure 1.
[0047] Figure 11 presents a schematic process flow diagram showing the inlet integration of the Be-CAP system, connected to the upstream of existing technologies as a pre-treatment process.
[0048] Figure 12 illustrates a schematic process flow diagram of the outlet integration of the Be-CAP system, showing its role as a post-treatment process in connection with existing technologies.
[0049] Figure 13 illustrates a schematic process flow diagram of the absorption of gaseous pollutant of Be-CAP system, showing its integration with the simple water spray tower.
[0050] Figure. 14. Iso-metric view of another integrated module of Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) system with Cyclone as pre-separator device to reduce dust concentration.
[0051] Although the specific features of the present invention are shown in some drawings and not in others. This is done for convenience only as each feature may be combined with any or all of the other features in accordance with the present invention.

F) DETAILED DESCRIPTION OF THE INVENTION
[0052] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.
[0053] The various embodiments of the present invention disclose a Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP), a method and system aimed at enhancing the removal of fine particulate matter (PM2.5) from industrial flue gas streams. This innovative technology integrates combination of positive and negative electrostatic charging and cyclonic motion to facilitate the agglomeration of fine dust particles, allowing for more effective removal in subsequent filtration systems. The Be-CAP system is designed to work as a pre-treatment or post-treatment solution for existing industrial air pollution control technologies, improving their overall performance while maintaining operational efficiency.
[0054] In one embodiment, the invention utilizes an Electrostatic Charger Configuration (ECC) to generate both positive and negative ions that charge dust particles with opposite polarities. Half of the dust particles in the flue gas stream are exposed to a positive electric field, while the other half is exposed to a negative field. This step is critical, as the bipolar charging creates an electrostatic force of attraction between the oppositely charged particles, encouraging collisions during the cyclonic motion phase. By focusing on charging particles separately, the invention maximizes the chances of forming larger dust particle agglomerates when the particles are introduced into the cyclonic chamber.
[0055] Following the charging step, the particles are introduced into a Cyclonic Agglomeration Process (CAP). The cyclonic motion within the chamber significantly increases the likelihood of collisions between the oppositely charged particles. These collisions result in the formation of larger agglomerates, which are easier to remove in downstream filtration stages. The cyclonic motion generates centrifugal forces that push the particles outward, further aiding in the particle aggregation process. This mechanical force complements the electrostatic attraction between the oppositely charged particles, resulting in highly efficient particle agglomeration.
[0056] Another embodiment of the invention describes the integration of the Electrified Cyclonic Agglomeration Process (e-CAP). In this process, the cyclonic motion is enhanced by an additional electric field, which further boosts the efficiency of the particle agglomeration. The e-CAP system combines both centrifugal and electrostatic forces to ensure that even the finest PM2.5 particles are captured and aggregated into larger particles. The use of the e-CAP provides an additional layer of filtration, making it a valuable tool for industries that face stringent emission regulations.
[0057] One of the key advantages of the Be-CAP system is its ability to retrofit with existing pollution control technologies. The system can be installed as a pre-treatment device upstream of technologies like electrostatic precipitators, bag filters, or cyclones. When used as a pre-treatment, the Be-CAP system helps reduce the concentration of fine particulate matter before the flue gas enters the primary filtration system, thus enhancing the overall efficiency of the setup. Alternatively, the Be-CAP can be applied as a post-treatment process downstream of existing systems, capturing any fine particles that may have escaped the primary filtration units.
[0058] Another key advantage of the Be-CAP system is its absorption of SO2 and NO. The Be-CAP process also converts the simultaneously sulphur di-oxides (SO2), nitrogen monoxides (NO) to sulphur tri-oxide (SO3) and other higher oxides of nitrogen like nitrous oxide (N2O), di-nitrogen pentoxide (N2O5) and on simple water spray absorbs the gaseous pollutants discharging a clean gas to the atmosphere.
[0059] The invention is highly versatile and can be applied across various industries where PM2.5 emissions are a concern, including power plants, steel mills, cement factories, and other industrial facilities. The flexibility in application makes it suitable for both large-scale industrial setups and smaller facilities, providing a scalable solution for reducing particulate emissions. Because the Be-CAP system focuses on removing fine particulate matter, it is especially relevant in industries where emissions of PM2.5 are subject to regulatory controls and environmental standards.
[0060] From a technical perspective, the Be-CAP process addresses a major challenge faced by conventional air pollution control technologies: their limited ability to remove fine particulate matter. While conventional systems like cyclones and electrostatic precipitators are effective at removing larger particles, they struggle to capture particles in the sub-2.5-micron range. By leveraging both electrostatic forces and cyclonic motion, the Be-CAP system ensures that even the smallest particles are efficiently agglomerated and removed, providing a significant improvement over existing solutions.
[0061] In addition to its high efficiency, the Be-CAP process is designed to be cost-effective. Unlike other advanced filtration methods that require substantial energy inputs or large-scale infrastructure modifications, the Be-CAP system can be integrated into existing setups with minimal energy consumption and pressure drops. This feature reduces the operational costs for industries while maintaining compliance with stringent emission standards. The system's ability to achieve high performance without major increases in energy usage makes it an attractive option for companies looking to reduce their environmental footprint without sacrificing economic efficiency.
[0062] The environmental benefits of the Be-CAP process are significant. By capturing fine particulate matter more effectively, the system helps reduce the release of PM2.5 into the atmosphere, which is known to cause severe health problems, including respiratory issues, cardiovascular diseases, and premature death. The reduction of PM2.5 emissions not only benefits public health but also helps industries comply with national and international air quality regulations. As governments continue to tighten pollution control standards, technologies like Be-CAP will play an increasingly important role in achieving cleaner air.
[0063] One of the distinguishing features of the Be-CAP system is its ability to handle multiple streams of flue gas. The system can be configured to divide the main flue gas stream into multiple sub-streams, each of which is treated with a separate Electrostatic Charger Configuration (ECC). This modular approach allows the Be-CAP system to be tailored to the specific needs of different industrial processes, ensuring optimal performance regardless of the flue gas composition or particulate load. The ability to treat multiple sub-streams simultaneously makes the system highly efficient in handling large volumes of gas.
[0064] The design of the Electrostatic Charger Configuration (ECC) is another key innovation in the Be-CAP process. The ECC consists of integrated discharge and collector electrode assemblies that generate positive and negative electric fields. The electrodes are arranged in such a way that the dust particles passing through the ECC are uniformly charged, ensuring consistent performance in the agglomeration stage. The discharge-collector electrode assembly is designed to handle high-frequency, high-voltage power supplies, further enhancing the system's ability to generate strong electrostatic fields for particle charging.
[0065] Additionally, the Be-CAP process includes agglomerate dust hoppers that collect the large dust particle agglomerates formed during the cyclonic agglomeration phase. These hoppers are strategically placed at the bottom of the cyclonic chamber to ensure efficient collection and removal of the agglomerates. The collected agglomerates can then be safely disposed of or recycled, depending on the composition of the dust particles and the needs of the specific industry.
[0066] In another embodiment, the Be-CAP system is designed to be easily scalable. The size and capacity of the system can be adjusted to meet the needs of different industrial applications, from small manufacturing plants to large power generation facilities. This scalability ensures that the Be-CAP system can be applied across a wide range of industries, providing a flexible and adaptable solution for reducing particulate emissions.
[0067] Finally, the innovative combination of cyclonic motion and electrostatic forces makes the Be-CAP system a unique solution in the field of air pollution control. By integrating these two mechanisms, the invention overcomes the limitations of traditional filtration technologies and provides a highly efficient means of capturing fine particulate matter. The system's ability to enhance the performance of existing technologies while minimizing energy consumption and operational costs makes it a valuable tool for industries seeking to reduce their environmental impact.
[0068] Figure 1 illustrates an isometric view of the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) (100) system, featuring a single Electrostatic Charger Configuration (ECC) (118), according to an embodiment of the invention. According to the embodiment, the primary feature of the system is the Electrostatic Charger Configuration (ECC) (118), which plays a pivotal role in charging the dust particles in the flue gas stream. The ECC is designed to generate both positive and negative electric fields, effectively charging the particles as they pass through. This configuration includes both discharge and collector electrodes that are positioned to maximize the charging efficiency of fine particulate matter (PM2.5). The flue gas enters the system through the main inlet duct (113), where it is introduced to the charging stage.
[0069] As the flue gas enters the diverging duct (114), its velocity is reduced, which ensures uniform distribution of the gas stream into the bottom sub-stream ducts (115). The diverging duct (114) is critical as it minimizes turbulence and maintains a steady laminar flow of gas, improving the effectiveness of the electrostatic charging process. Coarse dust particles that are too large to be effectively charged by the ECC (118) tend to settle out in the ash hopper (116) due to the drop in gas velocity of order less than 1m/s. This ash hopper collects these larger particles, preventing them from progressing through the system and enabling their eventual disposal via the coarse particle outlet (117).
[0070] Once the gas stream is laminar flow distributed in ECC (118) and the particles are charged with opposite polarity, the next phase involves the separation of particles through either the Cyclonic Agglomeration Process (CAP) (136) or the Electrified Cyclonic Agglomeration Process (e-CAP) (137), depending on the specific configuration. The charged particles experience cyclonic motion within the chamber of central hallow cylindrical mixing shell (101), causing them to collide and form larger agglomerates. These larger agglomerates are easier to filter out in subsequent stages. Figure 1 provides a clear representation of how the Be-CAP (100) system integrates various components, from the main inlet ducts (113) to the ECC (118) and ash hopper (116), to effectively manage and process fine particulate matter in industrial flue gas streams.
[0071] Figure 2 illustrates an isometric view of the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) (100) system apparatus with multiple Electrostatic Charger Configurations (ECCs) (118), according to an embodiment of the invention. According to the embodiment, the inclusion of several ECCs (118) is designed to enhance the efficiency of particle charging by providing a more extensive electrostatic charging field. Each ECC (118) in this configuration generates either a positive or negative electric field, ensuring that a larger volume of dust particles in the flue gas stream is charged more effectively, improving the chances of particle agglomeration in subsequent stages. This configuration is particularly useful in industrial settings where large volumes of flue gas must be processed quickly and effectively.
[0072] The flue gas enters the system through the main inlet duct (113), where it is distributed into multiple sub-stream ducts (115) that lead to each individual ECC (118). The use of multiple sub-stream ducts (115) ensures that the flue gas is evenly distributed across all the ECCs (118), maximizing the exposure of dust particles to the electrostatic fields. This uniform distribution is key to enhancing the overall efficiency of the Be-CAP (100) system, as it increases the likelihood that fine particulate matter (PM2.5) will be properly charged and agglomerated in the following steps. The diverging duct (114) also plays a role in maintaining this uniform flow by reducing the velocity of the gas stream, further improving the charging process.
[0073] In this multiple ECC (118) configuration, the system is particularly suited for larger industrial applications where the volume of flue gas and the concentration of particulate matter are higher. The multiple ECC (118) units work in tandem to ensure that particles are adequately charged, preparing them for agglomeration in either the Cyclonic Agglomeration Process (CAP) (136) or the Electrified Cyclonic Agglomeration Process (e-CAP) (137). As in Figure 1, coarse dust particles that are too large to be efficiently charged by the ECCs (118) settle out in the ash hopper (116), ensuring that only appropriately sized and charged particles continue through the system. This configuration allows for greater flexibility and scalability, making it a versatile solution for industries that need to process large amounts of particulate-laden flue gas while complying with stringent air quality regulations.
[0074] Figure 3 shows a cross-sectional view of the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) (100), corresponding to Figures 1 and 2. According to the embodiment, this cross-sectional view emphasizes the role of both the Electrostatic Charger Configurations (ECCs) (118) and the Cyclonic Agglomeration Process (CAP) (136), as well as the Electrified Cyclonic Agglomeration Process (e-CAP) (137). The flue gas stream (112), containing dust particles, enters through the inlet duct (113) and is then directed into the diverging duct (114), which plays a vital role in reducing the gas velocity to improve the uniformity of particle distribution. This structure ensures that the gas is evenly spread before entering the ECCs (118), where the dust particles are charged either positively or negatively.
[0075] In this embodiment, the multiple sub-stream ducts (115) divide the flue gas into smaller streams before it reaches the ECCs (118), improving the efficiency of particle charging. The cross-section shows how each ECC (118) is positioned to charge the dust particles passing through with either a positive or negative electric field. The positively and negatively charged particles are then directed into the Cyclonic Agglomeration Process (CAP) (136) or the Electrified Cyclonic Agglomeration Process (e-CAP) (137), depending on the configuration. Inside the CAP (136) or e-CAP (137), the particles undergo cyclonic motion, which increases their chances of more interaction between the particles results in collision colliding and agglomerating into larger particles. The combination of centrifugal forces from the cyclonic motion and the electrostatic attraction between oppositely charged particles makes the agglomeration process highly efficient.
[0076] At the bottom of the system, the ash hopper (116) collects larger, coarse particles that settle out of the gas stream due to the drop in velocity in the diverging duct (114). This prevents these larger particles from progressing further into the system, ensuring that only fine, charged particles continue into the agglomeration chamber. The cross-sectional view also highlights the overall flow of gas through the system, demonstrating how the gas moves through the ECCs (118), undergoes cyclonic agglomeration, and finally exits the system as clean gas (104) through the vortex tube (103). The design of the system ensures optimal particle removal while maintaining a streamlined gas flow, allowing for both efficient particle agglomeration and easy disposal of large agglomerates (109) collected in agglomeration dust hopper (110).
[0077] Figure 4 illustrates a top cut-away perspective isometric view depicting a distinct embodiment of the Cyclonic Agglomeration Process (CAP) (136), according to the present invention. According to the embodiment, the central hollow cylindrical mixing shell (101), which is the main chamber where the agglomeration of dust particles occurs. The flue gas stream (106), carrying a mixture of positively charged fine dust particles and negatively charged large dust particles, enters the system through the opposite tangential sub-stream inlet ducts (102). These inlets are positioned in such a way that they create a cyclonic motion inside the mixing shell, causing the particles to move in a spiral pattern. This cyclonic action significantly increases the likelihood of collisions between oppositely charged particles, leading to the formation of larger dust particle agglomerates (109).
[0078] The cyclonic motion causes the larger agglomerates to be pushed towards the outer walls of the central hallow cylindrical mixing shell (101) due to centrifugal forces. At one end of the shell, the vortex tube (103) is co-axially connected, allowing the clean gas (104) to exit the system through the clean gas outlet passage (105). The hollow cylindrical separation shell (111) helps create a concentric air gap, which further aids in separating the large agglomerates from the flue gas. The larger agglomerates particles are directed downward into the agglomerate dust hopper (110), located at the bottom of the hollow cylindrical separation shell (111), where they are stored for eventual disposal. This detailed design ensures efficient particle agglomeration and separation, optimizing the removal of fine particulate matter from the gas stream.
[0079] Figure 5 provides a cross-sectional view of the Cyclonic Agglomeration Process (CAP) (136), corresponding to Figure 4, showing the flue gas sub-stream inlet (102), central hallow cylindrical mixing shell (101), and clean gas outlet passages (105). According to the embodiment, the flue gas stream (106) entering the system apparatus through the opposite tangential sub-stream inlet ducts (102), which initiate the cyclonic motion necessary for particle separation. As the gas stream swirls within the hollow cylindrical mixing shell (101), the positively charged fine dust particles and negatively charged larger dust particles are mixed together, facilitating collisions that result in the formation of larger agglomerates (109). The swirling motion is sustained by the cyclonic forces, driving the agglomerated particles toward the walls of the central hallow cylindrical mixing shell (101), where they can be more easily separated from the clean gas (104).
[0080] As the gas continues to circulate, the clean gas (104) is directed upwards through the vortex tube (103), exiting via the clean gas outlet passage (105). Meanwhile, the larger agglomerated particles, due to their higher mass, settle toward the bottom of the system, where they are collected in the agglomerate dust hopper (110), positioned in the lower portion of the hollow cylindrical separation shell (111). This cross-sectional design highlights the effectiveness of the CAP (136) in separating fine particulate matter from the gas stream, ensuring that clean gas (104) is expelled from the system, while the larger agglomerates particles are stored for disposal or further processing. The system is optimized for efficiency, allowing for continuous operation without interruptions for cleaning, which is critical in industrial applications.
[0081] Figure 6 shows a top cut-away perspective isometric view illustrating a distinct embodiment of the Electrified Cyclonic Agglomeration Process (e-CAP) (137) with a combined charging unit. According to the embodiment, at the center is the hollow cylindrical mixing shell (101), which acts as the main chamber where the flue gas stream (106) containing a mixture of positively charged fine particles and negatively charged larger particles enters through the opposite tangential sub-stream inlet ducts (102). These inlets are designed to create cyclonic motion within the chamber, causing the particles to swirl and collide with each other. However, in this embodiment, the particle agglomeration process is enhanced by the addition of a discharge electrode (107), which is placed co-axially along the center of the hallow cylindrical mixing shell (101).
[0082] The discharge electrode (107) plays a critical role in generating either a positive or negative electric field, powered by a high-frequency, high-voltage power supply. This electrode enhances the efficiency of particle agglomeration by adding an additional electrostatic force to the process. As the particles are subjected to both centrifugal forces from the cyclonic motion and electrostatic attraction or repulsion, their chances of colliding and forming larger agglomerates are significantly increased. This combination of forces ensures that the e-CAP (137) process is more efficient at capturing and removing fine particulate matter (PM2.5) from the flue gas stream than a purely mechanical cyclonic process. The detailed view in Figure 6 illustrates how these components work together to create a more robust and effective agglomeration system for industrial air pollution control.
[0083] Figure 7 offers a cross-sectional view of the e-CAP (137), corresponding to Figure 6, detailing the flue gas sub-stream inlet (102), large agglomerates collection (109), and clean gas outlet passages (105). According to the embodiment, the flue gas enters the hollow cylindrical mixing shell (101) through the opposite tangential sub-stream inlet ducts (102). This entry setup creates a cyclonic motion inside the chamber, where the dust particles-comprising positively charged fine particles and negatively charged larger particles-are swirled together. The cyclonic action drives the particles toward the outer edges of the mixing shell due to centrifugal forces, where they are more likely to collide and agglomerate.
[0084] The defining feature of Figure 7 is the co-axially positioned discharge electrode (107), which runs along the center axis of the hallow cylindrical mixing shell (101). Powered by a high-frequency, high-voltage power supply, this electrode generates a strong electrostatic field that enhances the agglomeration of the particles by electrostatic attraction or repulsion. As the particles continue swirling due to the cyclonic motion, the combined effects of electrostatic force and centrifugal force significantly improve the formation of larger particle agglomerates, allowing for more efficient separation of fine particulate matter from the gas stream. This cross-sectional view clearly shows how the e-CAP (137) process integrates mechanical and electrostatic forces to create a more effective method for removing fine particulate matter (PM2.5) from industrial flue gases.
[0085] Figure 8 illustrates a cross-sectional view of the Electrostatic Charger Configuration (ECC) (118), showing the discharge-collector electrode assembly (131). According to the embodiment, the Electrostatic Charger Configuration (ECC) (118), which is a key component used to generate either a positive or negative electric field, or a combination of both, for charging dust particles (108). The ECC (118) is powered by a high-frequency, high-voltage power supply, enabling it to effectively charge particles in the flue gas stream. The hollow rectangular section (130) houses integrated discharge-collector electrode assemblies (131), arranged in multiple parallel passages to optimize the charging process. This design enhances the efficiency of charging fine particulate matter (PM2.5) as the particles move through the ECC (118).
[0086] At the bottom of the ECC (118), the resting plate (129) distributes the impact load onto the bottom connecting holder (128), which is suspended using a helical spring (127) to provide damping. This spring setup ensures that any vibrations or forces generated during operation are absorbed, maintaining the stability of the electrode assembly. The cross plate aligner (126) is positioned to ensure that the entire discharge-collector electrode assembly (131) remains properly aligned, which is crucial for consistent and effective particle charging.
[0087] At the top of the ECC (118), the top connecting holder (122) extends through the top aligner sleeve (120) and is fitted with a boot seal (121) on the ECC flange (119) for self-alignment. This top connecting holder (122) plays a vital role in transferring the impact load evenly through the top resting plate (125) to the discharge collector electrode assembly (131). Additionally, the magnetic-impulse rapping system (124), featuring a rapper plunger (123), is intermittently operated to apply impact vibrations, helping to dislodge any dust particles that have adhered to the discharge-collector electrode assembly. (131) These dislodged particles then settle and are collected in the ash hopper (116) through the passage of the bottom sub-stream duct (115). The overall configuration ensures the continuous and efficient charging and removal of dust particles, allowing for effective electrostatic agglomeration in subsequent stages of the process.
[0088] Figure 9 provides a cross-sectional view of the integrated discharge-collector electrode assembly (131). According to the embodiment, the integrated discharge-collector electrode assembly (131), which is an essential component of the Electrostatic Charger Configuration (ECC) (118) consists of multiple discharge electrodes (138), arranged in parallel passages relative to the collector electrodes (134). The two sets of electrodes are separated by dielectric material (135), which serves as a high-voltage insulation, ensuring that the discharge electrode (138) and collector electrodes (134) maintain their respective electric fields without interference. The role of the dielectric material (135) is to isolate the electric charges, enabling the generation of strong positive or negative electric fields required to charge the dust particles (108) as they pass through the ECC (118).
[0089] The collector electrode (134) is designed as a flat sandwiched plate and is housed within a square collector frame (133), ensuring structural integrity. This frame is coupled with a top resting plate (132) that ensures the assembly remains straight and aligned. The top resting plate (132) also reinforces the structure to withstand the vibrations caused by the impact load during operation. The discharge-collector electrode assembly (131) is central to generating the electrostatic field that charges the dust particles, ensuring they are properly prepared for the agglomeration process. The robust design of this assembly ensures that it can handle the high-voltage conditions necessary for the efficient operation of the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) (100).
[0090] Figure 10 depicts a schematic process flow diagram of the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) (100) system apparatus, corresponding to Figure 1. According to the embodiment, the diagram provides a comprehensive view of how the flue gas stream containing dust particles (108) moves through various stages of charging and agglomeration. Initially, the main flue gas stream is divided into sub-streams, with half of the dust particles passing through a positively charged Electrostatic Charger Configuration (ECC) (118) and the other half passing through a negatively charged ECC (118). This step ensures that the dust particles (108) acquire either a positive or negative charge, depending on which path they take.
[0091] Once the dust particles are charged, they enter the Cyclonic Agglomeration Process (CAP) (136) or the Electrified Cyclonic Agglomeration Process (e-CAP) (137). In these processes, the charged particles experience cyclonic motion, which facilitates collisions between oppositely charged particles. These collisions cause the particles to agglomerate into larger agglomerates (109), making them easier to remove from the gas stream. The combined electrostatic and centrifugal forces enhance the efficiency of agglomeration, ensuring a higher capture rate of fine particulate matter (PM2.5).
[0092] After the agglomeration process, the larger dust particle agglomerates (109) are collected in an agglomerate dust hopper (110), where they are stored for eventual disposal. The clean gas (104), now free from a significant portion of particulate matter, is discharged from the system. Figure 10 provides a clear representation of how the Be-CAP (100) system efficiently charges, agglomerates, and removes dust particles from industrial flue gases, contributing to improved air quality and compliance with environmental standards.
[0093] Figure 11 presents a schematic process flow diagram showing the inlet integration of the Be-CAP (100) system, connected to the upstream of existing technologies as a pre-treatment process. According to the embodiment, the system is configured as a retrofit device and the primary objective of this pre-treatment design is to enhance the performance of existing air pollution control technologies such as cyclones (141), electrostatic precipitators (142), bag filters (143), and wet scrubbers (144). In this setup, the Be-CAP (100) device agglomerates fine dust particles into larger particles (109), which are then fed directly into the upstream of these existing filtration systems. By pre-treating the flue gas, the Be-CAP (100) process significantly improves the efficiency of these traditional technologies in capturing particulate matter.
[0094] The modified Be-CAP (100) system is integrated upstream of the current available technologies through connecting ducts (147), ensuring that the larger agglomerates formed in the Be-CAP (100) process are efficiently removed by the downstream systems. The clean gas then passes through an induced draft fan (145) and is discharged into the chimney (146). One of the key benefits of this retrofit design is that it introduces only a minimal pressure drop of 20 mmWC, which means it does not disturb or alter the operation of the existing induced draft fan. This feature reduces the operating costs and minimizes downtime during installation, making it a cost-effective solution for industries looking to improve their pollution control systems without major modifications.
[0095] Figure 12 illustrates a schematic process flow diagram of the outlet integration of the Be-CAP (100) system, showing its role as a post-treatment process in connection with existing filtration technologies. According to the embodiment, the Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) (100), is designed as a retrofit polishing device. This embodiment focuses on treating and collecting the fine dust particles that remain after passing through existing air pollution control technologies, such as cyclones (141), electrostatic precipitators (142), bag filters (143), and wet scrubbers (144). The post-treatment configuration works similarly to the pre-treatment process described in Figure 11, but its primary function is to further refine the filtration process by capturing any residual fine particles that may have escaped the primary filtration systems.
[0096] The retrofit polishing device is specifically designed to deliver the highest collection efficiency for fine particulate matter, ensuring that the emission levels meet the stringent government regulations. This makes the Be-CAP (100) system particularly valuable in industrial applications where compliance with air quality standards is critical. By incorporating this post-treatment process, industries can achieve compliance with outlet emission norms set by regulatory authorities. Moreover, this design is highly cost-effective, providing an alternative solution for industries looking to optimize their pollution control systems without the need for extensive infrastructure changes or significant increases in operational costs. The Be-CAP (100) retrofit device ensures that even the finest particles are captured, further enhancing the overall effectiveness of the existing filtration technologies.
[0097] Figure 13 illustrates a schematic process flow diagram of the absorption of gaseous pollutant of Be-CAP system, showing its integration with the simple water spray tower (148) for absorption of sulphur di-oxide (SO2) and Nitrogen monoxide (NO). Acorrding to the embodiment, The Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) (100), is designed as absorption of gaseous pollutants specifically sulphur di-oxides (SO2), nitrogen monoxides (NO) which are insoluble in water. So Be-CAP (100) also exhibits the conversion of sulphur di-oxides (SO2), nitrogen monoxides (NO) to sulphur tri-oxide (SO3) and other higher oxides of nitrogen like nitrous oxide (N2O), dinitrogen pentoxide (N2O5), which are highly soluble in water and on simple water spray tower (148) absorbs the gaseous pollutants discharging a clean gas to the atmosphere.
[0098] Figure. 14. Illustrates the Iso-metric view of another integrated module of Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) system, showing the cyclones (141) modular integration. According to the embodiment, Be-CAP (100) is integrated with Cyclones (141) as pre-separator device, to reduce the dust concentration to Be-CAP (100). And also to make compact, robust design as a replacement device to the current filtration technologies in order to meet the stringent emission norms.

G) ADAVANTAGES OF THE PRESENT INVENTION
[0099] The Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) offers several distinct advantages, particularly in the field of air pollution control. Following are the key advantages of the invention:
[00100] Efficient Removal of Fine Particulate Matter (PM2.5): The Be-CAP process effectively targets fine particulate matter (PM2.5), which is notoriously difficult to remove using conventional methods. By utilizing electrostatic charging combined with cyclonic agglomeration, the system enhances the likelihood of particle collisions, leading to the formation of larger agglomerates that can be easily captured and removed from the gas stream.
[00101] Enhanced Performance of Existing Technologies: The Be-CAP system can be retrofitted with existing pollution control devices such as cyclones, electrostatic precipitators, bag filters, and wet scrubbers, either as a pre-treatment or post-treatment device. This enhances the overall efficiency of these systems in capturing particulate matter, particularly fine particles that may otherwise escape.
[00102] Low Pressure Drop: One of the key benefits of the Be-CAP process is its ability to operate with minimal pressure drop (as low as 20 mmWC), meaning it does not interfere with the operation of existing fans or airflow systems. This leads to reduced energy consumption and lowers operational costs while maintaining high filtration efficiency.
[00103] Cost-Effective Retrofit Solution: The Be-CAP system is designed as a retrofit device, allowing industries to improve their pollution control without requiring significant infrastructure changes or investment in entirely new systems. This makes it a highly cost-effective solution for industries that need to comply with increasingly stringent air quality standards.
[00104] Scalability and Flexibility: The system can be scaled to suit different industrial applications, from small manufacturing units to large power plants. Its flexibility in handling various types of flue gases and particulate loads makes it a versatile solution across industries.
[00105] Combining Electrostatic and Cyclonic Forces: The unique combination of electrostatic charging and cyclonic agglomeration enhances particle separation efficiency. The system leverages both the electrostatic attraction between oppositely charged particles and the centrifugal forces generated by cyclonic motion to ensure higher capture rates for fine particulate matter.
[00106] High Collection Efficiency: The Be-CAP process delivers a high collection efficiency for fine dust particles, meeting or exceeding government regulatory standards for emissions. This ensures that industries can remain compliant with air quality regulations while minimizing their environmental impact.
[00107] Removal of SO2 and NO: The Be-CAP process also converts the simultaneously sulphur di-oxides (SO2), nitrogen monoxides (NO) to sulphur tri-oxide (SO3) and other higher oxides of nitrogen like nitrous oxide (N2O), dinitrogen pentoxide (N2O5) and on simple water spray absorbs the gaseous pollutants discharging a clean gas to the atmosphere.
[00108] Environmental and Health Benefits: By effectively reducing the emission of fine particulate matter, the Be-CAP process contributes to improved air quality and helps reduce the negative health impacts associated with PM2.5, including respiratory and cardiovascular issues. This leads to both environmental and public health benefits.
[00109] Reduced Maintenance and Downtime: The design of the system, including features like the agglomerate dust hopper and automated particle dislodging systems, minimizes the need for manual cleaning and maintenance, reducing operational downtime and enhancing productivity.
[00110] Energy Efficiency: The system operates with lower energy consumption compared to traditional filtration systems, as it integrates seamlessly with existing setups and does not require significant energy input for particle agglomeration and separation. This leads to long-term savings for industries in terms of both energy and operational costs.
[00111] In summary, the Be-CAP system is a highly efficient, flexible, and cost-effective solution for industrial air pollution control, especially in the removal of fine particulate matter PM2.5. Its ability to enhance the performance of existing technologies and comply with stringent regulatory standards makes it an ideal choice for industries aiming to reduce their environmental impact.
Dated this 10th Day of November 2024




Keerthi J S

Patent Agent - IN/PA-1729







To,
The Controller of Patents,
The Patent Office,
At Chennai
, Claims:CLAIMS
We Claim:
1. A Be-CAP (100) system for removing fine particulate matter (PM2.5) from a flue gas stream, comprising:
a. an Electrostatic Charger Configuration (ECC) (118), configured to generate both positive and negative electric fields to charge dust particles (108) within the flue gas stream (112), wherein the flue gas stream is divided into at least two sub-streams, with one sub-stream receiving a positive charge and the other receiving a negative charge;
b. a Cyclonic Agglomeration Process (CAP) (136) or Electrified Cyclonic Agglomeration Process (e-CAP) (137), wherein the positively and negatively charged dust particles are introduced into a hollow cylindrical mixing shell (101) via opposite tangential sub-stream inlet ducts (102), inducing cyclonic motion that causes collisions between the particles and leads to the formation of large dust particle agglomerates (109);
c. a vortex tube (103) for clean gas (104) exit, and an agglomerate dust hopper (110) to collect and store the large dust particle agglomerates (109).
wherein the combination of electrostatic charging and cyclonic motion enhances the capture efficiency of fine particulate matter.
2. A Be-CAP (100) system also used for purification of gaseous pollutants specifically for absorption of sulphur di-oxide (SO2) and nitrogen monoxide (NO) by passing through the simple water spray tower.
3. The system of claim 1, wherein the ECC (118) comprises
a. multiple integrated discharge-collector electrode assemblies (131), arranged in parallel passages within a hollow rectangular section (130), configured to charge the dust particles (108) using either positive or negative electric fields;
b. a discharge electrode (138) and a collector electrode (134), separated by a dielectric material (135) to ensure high-voltage insulation, wherein the discharge and collector electrodes generate electrostatic fields to charge the particles.
4. The system of claim 1, wherein the ECC (118) includes a magnetic-impulse rapping system (124) with a rapper plunger (123) designed to intermittently apply impact vibrations to dislodge dust particles adhering to the integrated discharge-collector electrode assembly (131), enabling efficient cleaning of the electrodes.
5. The system of claim 1, further comprising a diverging duct (114) connected to the main inlet duct (113) that reduces the velocity of the flue gas stream (112) and distributes it evenly into bottom sub-stream ducts (115) connected to the ECCs (118).
6. The system of claim 1, wherein the Cyclonic Agglomeration Process (CAP) (136) or Electrified Cyclonic Agglomeration Process (e-CAP) (137) includes a co-axially positioned discharge electrode (107) within the hollow cylindrical mixing shell (101), generating an additional electric field to enhance particle agglomeration through combined centrifugal and electrostatic forces.
7. The system of claim 1, wherein the system is configured as a pre-treatment device upstream of existing pollution control technologies, including a cyclone (141), electrostatic precipitator (142), bag filter (143), or wet scrubber (144), where the agglomerated particles are introduced for further filtration.
8. The system of claim 1, wherein the system is configured as a post-treatment device downstream of existing pollution control technologies, such that the fine dust particles not captured by the upstream technologies are agglomerated and collected in the agglomerate dust hopper (110).
9. A method of removing fine particulate matter (PM2.5) from a flue gas stream, comprising:
a. charging the dust particles (108) in the flue gas stream (112) with either a positive or negative charge through an Electrostatic Charger Configuration (ECC) (118);
b. introducing the charged particles into a Cyclonic Agglomeration Process (CAP) (136) or Electrified Cyclonic Agglomeration Process (e-CAP) (137) via opposite tangential sub-stream inlet ducts (102) to induce cyclonic motion;
c. allowing the charged particles to collide and form large agglomerates (109) due to the combination of electrostatic forces and centrifugal forces;
d. collecting the large agglomerates (109) in an agglomerate dust hopper (110) for disposal.
10. The system of claim 2, wherein the Be-CAP (100) converts the simultaneously sulphur di-oxides (SO2), nitrogen monoxides (NO) to sulphur tri-oxide (SO3) and other higher oxides of nitrogen like nitrous oxide (N2O), dinitrogen pentoxide (N2O5) and later on simple water spray absorbs the gaseous pollutants discharging a clean gas to the atmosphere.
11. The method of claim 8, wherein the flue gas stream is processed with minimal pressure drop, ensuring that the system operates efficiently without altering the performance of the induced draft fan (145) and downstream systems.
12. The system of claim 1, wherein the system is designed to be a cost-effective retrofit device, minimizing operational costs while enhancing the overall efficiency of particulate matter removal, ensuring compliance with regulatory emission standards.
13. The system of claim 1, wherein the agglomerate dust hopper (110) is designed to facilitate automatic dust particle discharge, reducing the need for manual intervention and enabling continuous operation of the system.
14. The system of claim 1, wherein the flue gas stream (112) undergoes a preliminary filtering step prior to entering the Electrostatic Charger Configuration (ECC) (118), ensuring that larger particles are removed before electrostatic charging.
15. The system of claim 1, wherein the discharge electrode (138) and collector electrode (134) are coated with corrosion-resistant materials to enhance the durability and longevity of the electrostatic charging unit in industrial environments.
16. The system of claim 1, wherein the Electrostatic Charger Configuration (ECC) (118) includes a feedback control system to adjust the strength of the electric field based on real-time measurements of the particle load in the flue gas stream (108).
17. The system of claim 1, wherein the system further comprises a temperature control unit that regulates the temperature of the flue gas stream (112) to optimize the charging and agglomeration process, preventing excessive condensation or high-temperature interference with the electrostatic field.
18. The method of claim 8, wherein the method further includes a step of monitoring the size distribution of the particulate matter agglomerates (109) formed during the agglomeration process, ensuring consistent performance in different flue gas compositions.
19. The system of claim 1, wherein the system is integrated with a sensor array for detecting gas velocity, particulate concentration, and humidity levels, allowing for dynamic adjustment of the electrostatic field and cyclonic motion parameters to improve agglomeration efficiency.
20. The system of claim 1, wherein the vortex tube (103) is equipped with an adjustable outlet to control the flow rate of clean gas (104) exiting the system, optimizing the system's overall performance under varying operational conditions.
21. The system of claim 1, wherein the cyclonic mixing shell (101) is made from heat-resistant materials to ensure reliable performance when handling high-temperature flue gases typically found in industrial processes.
22. The system of claim 1, wherein the entire system is modular in design, allowing for easy disassembly, replacement, or upgrading of key components such as the Electrostatic Charger Configuration (ECC) (118), discharge electrode (138), or agglomerate dust hopper (110) to meet changing industrial requirements.
23. A method for optimizing the efficiency of particulate matter removal from a flue gas stream, comprising:
a. dividing the flue gas stream (112) into multiple sub-streams, each processed by separate Electrostatic Charger Configurations (ECC) (118) to charge the dust particles (108) with positive or negative polarity;
b. controlling the strength and duration of the electrostatic charge using a real-time feedback loop to maximize particle agglomeration.

24. The method of claim 21, further comprising of adjusting the cyclone speed and turbulence inside the Cyclonic Agglomeration Process (CAP) (136) or Electrified Cyclonic Agglomeration Process (e-CAP) (137) based on the density of particles in the flue gas stream to ensure higher collision rates between charged particles.
25. A method of integrating a Bi-polar Electrified Cyclonic Agglomeration Process (Be-CAP) into an industrial air filtration system, comprising, retrofitting the Be-CAP system (100) as a pre-treatment process to an existing cyclone (141), electrostatic precipitator (142), bag filter (143), or wet scrubber (144), wherein the agglomerates formed by the Be-CAP system are directed into the downstream technology for further filtration.

Dated this 10th Day of November 2024


Keerthi J S

Patent Agent - IN/PA-1729



To,
The Controller of Patents,
The Patent Office,
At Chennai

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