air-pollution-control

What this skill does

# Air Pollution Control Design Skill

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

## Purpose

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

## Capabilities

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

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

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

### Thermal and Catalytic Oxidizer Specification
- Destruction efficiency requirements
- Temperature and residence time
- Heat recovery options (regenerative, recuperative)
- Catalyst selection for catalytic oxidizers
- Auxiliary fuel requirements
- Turndown capabilities

### Carbon Adsorption System Design
- Activated carbon selection
- Adsorption capacity calculations
- Breakthrough time estimation
- Bed sizing
- Regeneration system design
- Carbon replacement frequency

### Control Efficiency Calculations
- Outlet emission rate determination
- Removal efficiency verification
- Stack testing correlation
- Continuous monitoring requirements

### Pressure Drop and Energy Analysis
- System pressure drop calculation
- Fan power requirements
- Operating cost estimation
- Energy optimization opportunities

### BACT/LAER/MACT Determination
- Control technology identification
- Cost-effectiveness analysis
- Technical feasibility evaluation
- Regulatory database research
- Top-down BACT analysis

## Prerequisites

### Installation
```bash
pip install numpy scipy pandas matplotlib
```

### Optional Dependencies
```bash
# For chemical property lookup
pip install chemicals thermo

# For visualization
pip install plotly
```

## Usage Patterns

### Baghouse Design
```python
import numpy as np
from dataclasses import dataclass
from typing import Dict, List, Optional

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

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

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

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

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

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

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

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

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

        filter_area = gas.flow_rate_acfm / ac_ratio

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

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

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

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

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

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

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

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

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

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

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

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

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

### Wet Scrubber Design
```python
class WetScrubberDesign:
    """Wet scrubber design calculations"""

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