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Electrostatic Precipitators
Electrostatic Precipitators
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ESP Presentation
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Index
Controlling Air Pollution
Introduction
Design Features
Principle of Operation
Components
Operations & Performance
Corona Power
Maintenance & Troubleshooting
About Us
Index
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Controlling Air Pollution
Clean Air is an essential resource to the
people
surrounding
the
Industrial
Cont
Air pollution
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Controlling Air Pollution
Now a days Electrostatic Precipitators
have come a long way and are widely
used in all major Power Plants, Chemical
Industries, Cement Industries & Steel
Industries. They absorb more than 99%
of dust particles and other substances
while
exhaust
are
with
the
Emission
Standard
Air pollution
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Electrostatic Precipitators
In all industries the burnt gases are passing through an Equipment called Electrostatic
Precipitator to eliminate the dust particles.
In the simplest terms, a Precipitator is a large box. The dust-laden gases are drawn into
one side of the box. Inside, high voltage electrodes impart a negative charge to the
particles entrained in the gas. These negatively charged particles are then attracted to a
grounded collecting surface, which is positively charged.
The gas then leaves the box up to 99.9% cleaner than when it entered.
Introduction to ESP
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Electrostatic Precipitators
Electrostatic Precipitator removes dust particles
from the exhaust gas stream of a process
industry.
Often,
the
process
involves
combustion, but it can be any industrial
process that would otherwise emit dust
particles to the atmosphere. There are six
activities that take place:
Ionization Charging of particles
Migration - Transporting the charged
particles to the collecting surfaces
Collection - Precipitation of the charged
particles onto the collecting surfaces
Charge dissipation - Neutralizing the
charged particles on the collecting surfaces
Particle dislodging - Removing the
particles from the collecting surface to the
hopper
Particle removal - Conveying the particles
from the hopper to a disposal point
Introduction to ESP
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Electrostatic Precipitators
other industries (for other exhaust gas particles) such as Cement (dust), Pulp &
Paper (salt cake & lime dust), Petrochemicals (sulfuric acid mist), and Steel
& fumes).
Introduction to ESP
(dust
IMECO LIMITED
History of Electrostatic
Precipitator Technology
Introduction to ESP
these
design
precepts
are
still
almost
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Status of Electrostatic Precipitator
Technology usage in India
Electrostatic Precipitator (ESP) is the most
widely used device in India for particulate
emission control. Over the years, ESP
design has improved with the experiences
from
its
application
and
operation
in
manufacturers.
Efforts
to
improve
Introduction to ESP
IMECO LIMITED
Thermal Power Plants
In Thermal Power Stations,
suspended particulate matter
(SPM),
sulphur
dioxide
(SO2),
and
oxides
of
nitrogen (NOx) are the major
emissions, resulting from
fuel
combustion
during
power
generation.
To
generate 200 MW electrical
energy, the power station
consumes
about
2700
tonnes/day of coal producing
daily about 1200 tonnes of
ash and 216 tonnes of SO2.
Over a year, these work out to half a million tonne of ash and 80000 tonnes of SO2. The
total amount of pollutants from all the thermal power plants, if allowed to pervade our
atmosphere without any control, would seriously pose a threat to ecological balance,
climate, and atmosphere.
Cont.
Introduction to ESP
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THERMAL POWER PLANTS
ESPs are used in all thermal power plants to control particulate
emissions. Ash generated in a power plant has nearly 30 per cent
by weight in 10 m
range and 10 per cent in 2
m
range.
concentration
Also
of
dust
the
is
of
collecting
Introduction to ESP
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STEEL INDUSTRY
Dust emission problems in the sintering plant
of the Steel Factory mainly arise from the
exhaust gases from the combustion zones and
from the ventilation air out of crushers, sieves,
coolers, and loading stations. The average dust
emission level is about 1520 kg/tonne of sinter
which is returned to the process when collected.
Blast furnaces may have outputs upto 2000
3000 tonnes/24 hr. Waste gas is produced at a
rate of approximately 4000 m3 at STP per
tonne of pig iron with a dust content after
coarse separation of approximately 10 gm/m3.
The dust contained in the exhaust gas extracted
from the top of the blast furnace mainly
consists of iron oxide, silica, and lime.
Introduction to ESP
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CEMENT PLANTS
The use of ESPs in cement plants has been since its invention. This is due to its recovery
value and the finest and best cement can be collected through ESP. Use of ESP in cement
plants has dominated every market in the world. In India, there was raised growth during
70s and 80s. ESPs are generally used in cement kilns and cement grinding mills. In kiln
waste gas, the range of gas quantity is 150 000 m3/hr at a temperature of 250 C.
However, gas cooling tower brings down their temperature. In cement grinding mill, the
gas range is 45 000 m3/hr approximately at a temperature of 80 C. The application of
ESPs has undergone considerable change with the advent of new processes for cement
manufacture
(especially
the
introduction
of
dry
cement
manufacturing process) and also wider awareness of environmental
factors. The cement industries with the stringent air borne emission
standards have begun to use conventional ESPs for control of
emissions in kilns (in kilns ESPs were used together with conditioning
tower) and coal mills.
Since the dry process is widely being adopted by all the plants
including the old plants (with wet process converting to dry process),
the dust loading is increased and thus improved ESPs with Pulse
Energization techniques are used.
Introduction to ESP
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APPLICATIONS FOR
ELECTROSTATIC PRECIPITATORS
Introduction to ESP
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FEATURES / ADVANTAGES
Generally ESP
- can collect dust in both wet and dry conditions;
- can collect all sizes of particles, from microns
to coarsers;
- probably the most versatile collecting equipment;
- offers the highest efficiency, can be designed
in principle for any
- efficiency without excessive pressure drop;
- operates with low operation cost (though initial cost is more);
- can operate over a wide range of inlet conditions, i.e., temperature,
pressure, dust burden, humidity, etc.;
- offers negligible pressure drop (rarely crosses 1015 mm); can be built in
multiple units, for almost any gas volume;
- has a long life, comparatively free from abrasioneffect due to low operating
velocity;
Introduction to ESP
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ESP DESIGNS
ESPs
ESP - Designs
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TRADITIONAL ESP DESIGNS
ESP - Designs
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TRADITIONAL NORTH AMERICAN DESIGN
ESP - Designs
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TRADITIONAL EUROPEAN DESIGN
ESP - Designs
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PRINCIPLE OF OPERATION
Electrostatic precipitation is a physical process by which
particles suspended in gas stream are charged electrically, and
under the influence of electric field are separated from the gas
stream. The precipitation system consists of a positively
charged collecting surface and a high voltage discharge
electrode wire suspended from an insulator at the top and
held in position by a weight at the bottom. At a very high DC
voltage of the order of 50 kV, a corona discharge occurs close
to the negative electrode, setting up an electric field between
the emitter and the charged surface.
The particle-laden gas enters inlet side of ESP and flows through . The gas close to the
negative electrode is, thus, ionized upon passing through the corona. As the negative ions
and electrons migrate towards the charged surface, they in turn charge the passing
particles. The electrostatic field then draws the particles to the collector surface where they
are deposited. Periodically, the collected particles are removed from the collecting surface
by rapping or vibrating the collector to dislodge the particles. The dislodged particles drop
below the electrical treatment zone and are collected through hoppers for ultimate disposal.
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HOW A ESP FUNCTIONS
Charging
Particles are given strong negative
charge by ionizing corona produced
by high-voltage electrodes
Collection
The electric field causes charged
particles to migrate and precipitate on
the grounded plates, where they
agglomerate and are held by the
electric field
Removal
The
particulate
matter
is
mechanically rapped off the plates
in large clumps, falling into
hoppers for removal
ESP Principle of Operation
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TWO STAGE ELECTROSTATIC PRECIPITATOR
STAGE I
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TWO STAGE ELECTROSTATIC PRECIPITATOR
STAGE II
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SCHEMATIC OF A PARALLEL-PLATE PRECIPITATOR
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TYPICAL HORIZONTAL FLOW PRECIPITATOR
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COMPONENTS FOR
ELECTROSTATIC PRECIPITATORS
The devices used for gas solid separation,
Electrostatic Precipitators has the widest of
application in view of its various advantages. It
can handle Large volume of gases from which
solid
particles
components of
are
removed.
critical
indicated below.
COLLECTING ELECTRODE
PLAIN BEARING
SUPPORT INSULATOR
SHAFT INSULATOR
EMITTING ELECTRODE
SHOCK BAR
RAPPING HAMMERS
GAS SCREEN SHEET
ESP - Components
The
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COLLECTING ELECTRODES
Collecting plates are designed to receive and retain
the precipitated particles and then removed into the
hopper. In addition, the collecting plates are part of
the electrical power circuit of the precipitator. Baffle
plates shield the precipitated particles from the gas
flow.
And
smooth
surfaces
provide
for
high
ESP - Components
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DISCHARGE / EMIITING ELECTRODES
Discharge electrodes emit charging current and provide
voltage. This generates an electrical field between the
discharge electrodes and the collecting plates. The
electrical field forces dust particles in the gas stream to
migrate towards the collecting plates. Finally the
particles precipitate onto the plates. Common types of
discharge electrodes include
ESP - Components
Cont
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DISCHARGE / EMIITING ELECTRODES
Discharge electrodes are typically
supported
from
the
upper
frame
is
in
turn
casing.
High-voltage
ESP - Components
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DISCHARGE ELECTRODE TYPES
ESP - Components
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ELECTRODE ARRANGEMENT
ESP - Components
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ELECTRODE DESIGN (CONTD)
ESP - Components
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Advances in Electrode Design
Emitting (Discharge) Electrodes
Collecting Electrodes
ESP - Components
Ease of installation
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GAS DISTRIBUTION SCREENS
These Screens are of modular design manufactured out
of Steel sheets and hang within a frame work in the ESP
inlet casing to maintain uniform distribution pattern of
gas flow throughout the cross section of ESP.
Rapping
Mechanism
Shaft
for
ESP - Components
electrodes
is
through Shaft
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SUSPENSION AND RAPPING MECHANISM
The collecting electrodes are fixed loosely to
suspension beams on pins. They are joined
together in the bottom rapping beam. Both,
the
firm
bottom
and
the
top
loose
is
out
in
regular,
programmed
intervals
and
guarantees
removal
deposited
dust
from
electrodes
Tumbling
of
to
Hammers
the
Strike
the
hoppers.
the
collecting
ESP - Components
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HOPPERS
Precipitator hoppers are designed
to completely discharge their dust
load
on
demand.
Usually
the
ESP - Components
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MATERIALS OF CONSTRUCTION
ESP
Carbon Steel
Mild Steel
Corten
A516-70
Duplex & Stainless Steel
AR Plate
ESP - Components
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FACTORS INFLUENCING PERFORMANCE OF ESPS
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CORONA POWER
Precipitator corona power is the useful electrical power applied to the flue gas
stream to precipitate particles. Either precipitator collecting efficiency or outlet
residual can be expressed as a function of corona power in Watts/1000 acfm of
flue gas, or in Watts/1000 ft of collection area.
The separation of particles from the gas flow in an electrostatic precipitator
depends on the applied corona power. Corona power is the product of corona
current and voltage. Current is needed to charge the particles. Voltage is
needed to support an electrical field, which in turn transports the particles to
the collecting plates.
Cont
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CORONA POWER
In
the
lower
range
of
collecting
power
result
in
substantial
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OPTIMIZING CORONA POWER
Optimum conditions depend upon the location of the field (inlet, center, outlet), fly ash
characteristics (resistivity), and physical conditions (collecting plates and discharge wires).
Corona power levels can be optimized by adjusting or optimizing the following:
Gas velocity:
Uniformity
Fly ash:
Particle size
Resistivity
Voltage controls:
Design:
Plate spacing
Collecting plate and discharge
electrode design
Rapping system:
Support insulator:
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BackCorona
in the
Dust Layer
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RECOGNIZING BACK CORONA
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PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP
DAILY
WEEKLY
MONTHLY
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PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP
QUARTERLY
HALF YEARLY
ANNUAL
Cont
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PREVENTIVE MAINTENANCE CHECKLIST FOR A TYPICAL ESP
SITUATIONAL
Check all alarms, interlocks, and all other safety devices during
each outage.
Cont
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COMMON PROBLEMS WITH ESP
1.
2.
3.
4.
Electrode breakage
5.
6.
7.
8.
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MAJOR CAUSES OF PROBLEMS IN ESP
Problem
Causes
Excessive Gas
Volume
Rapping
Gas Distribution
Discharge
Electrode Breakage
Discharge Overflow
in Hoppers
Electrical
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TROUBLESHOOTING
DUST ACCUMULATION
The most common cause of excessive dust accumulation on electrodes is a failure of the rapper
control system. Unless there is reason to suspect otherwise (known high resistivity potential of the
ash or other indications of hopper plugging), this should be one of the first areas checked if power
input to the ESP decreases markedly. Checks of the control system will include:
i. Make sure that the power is on and that the fuse or circuit breaker has not been opened.
ii. Check for proper operation of the switch and drive on rotary switches.
iii. Check manufacturer recommended procedures for testing rapper control systems.
Rapper failure is also a potential cause of dust accumulation. The ESP's use magnetic
impulse/gravit impact type rappers.
A common cause of failure of this type
of rapper is a short in the coil that
lifts the rapper. Methods for correcting this
problem include:
i. Replace the defective rapper
with a new one.
ii. Rebuild the defective rapper.
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TROUBLESHOOTING
Corrective action for misalignment can only be done during a complete ESP shutdown. Corrective
actions include:
i) Plate straightening by: hydraulic press, localized heating with an oxy/acetylene torch followed
by water quench, remove the warped section of a plate with a cutting torch and replace it.
Major rebuilding will require removal of the top of the ESP and replacement of entire plates.
ii) Wire correction: Bent wire frames or lower guide frames often cause the wires to slacken and
bow towards the plates. Distorted lower guide frames are often difficult to straighten and may
have to be replaced. If the distortion is not too serious and only a few wires are slack, then
they can be removed. The wires can be tightened by crimping them in the direction of gas
flow.
iii) General misalignment caused by a shift in guide frame
components can usually be corrected by realigning the frame.
Air Infiltration
Routine inspections of the ESP will reveal any locations of air
infiltration into the unit. Correction of this problem involves
simple sealing of the leaking joint, surface or door/hatch gasket.
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START UP PRACTICES
i.
ii.
iii.
iv.
v.
When preparing for start-up, assure that all tools and safety devices (including lock
out/tag out) have been removed from or taken off of the controls of the ESP. The
plant superintendent or his designated representative shall be responsible for final
inspection of the ESP to determine that the unit is ready for start-up.
During the final pre-start-up inspection, the inspector shall assure that the ESP has
been properly closed up and the keys for the interlock system have been returned
to their appropriate locations.
Conduct an air load test for each T-R set and if possible, for each bus section. This
activity is used to determine that maintenance has been completed, all foreign
matter has been removed and that the ESP is ready for operation.
If the insulator heaters have been inspected during the shut-down, make sure that
they have been turned back on at least 2 - 12 hours prior to ESP start-up. Purge
air systems will also be activated at this time. Be aware of the potential for
particulates to pass through the system and be emitted to the atmosphere when
the purge air is activated.
The rapping system will be in operation during
start-up to remove any settled dust.
Energize the ESP according to procedures
established during
previous plant turnarounds.
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SHUTDOWN PRACTICES
Except in the instance of an emergency shutdown, this process should be essentially
the reverse of the start-up procedure.
A) Deenergization usually begins at the inlet fields and progresses toward the outlet. At
the point that the boiler is off-line, the fields (T-R sets) should be deenergized. This
should be done sequentially toward the ESP outlet and as quickly as possible to
prevent unnecessary sparking, condensation or insulator build-up.
B) The rappers should be allowed to operate for several hours to remove residual dust.
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SCHEDULE / PROCEDURE FOR RETROFITTING OF ESP
The
field
is
arrested
before
starting
any
cutting
operations
Cont..
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SCHEDULE / PROCEDURE FOR RETROFITTING OF ESP
After
releasing
the
temporary
ESP
is
full
load
charged
in
process.
the
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About Us
IMECO LIMITED
Our vision is to become a world class, innovative, competitive
engineering enterprise providing effective business solutions. Our
greatest strength lies in our highly skilled and committed work force,
who by continuous training and a positive and participative style of
management have engendered a work culture leading to enhanced
productivity and higher levels of quality.
We are constantly investing in resources for
product
development
with
an
objective
to
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OUR SERVICES
We offer services in the field of technical support as well as for supply of
internals / spares, both mechanical and electrical.
OUR SERVICES INCLUDE
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OUR PRODUCTS
WE HAVE COMPLETE MANUFACTURING FACILITIES FOR SUPPLY OF FOLLOWING SPARES
FOR ESP
COLLECTING ELECTRODES
DISCHARGE ELECTRODES
GAS SCREEN SHEETS
COLLECTING /DISCHARGE ELECTRODE FRAMES
RAPPING MECHANISM WITH SHAFTS AND
HAMMERS.
INNER AND OUTER ARMS FOR RAPPING
MECHANISM
HEATING ELEMENTS FOR HOPPER AND
SUPPORT INSULATOR
DISCONNECTING SWITCH ASSEMBLY
GEARED MOTORS
ALL MECHANICAL PARTS
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OUR ESTEEMED CUSTOMERS
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ESP SERVICES RELATED PROJECTS
National Aluminium
Company Ltd
Dishergargh Power
Supply Company Ltd
Indian Aluminium
Company Ltd
Bokaro Power Supply
Company Ltd
The Tata Iron & Steel
Company Ltd
Steel Authority of India
Ltd
Prakash Industries
Limited
My Home Power Limited
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CONTACT US
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KOLKATA - 700001
Tel : 91 33 2248 1888
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